Tri-Planar Geometric Dimensioning and Tolerancing Characteristics of SS 316L Laser Powder Bed Fusion Process Test Artifacts and Effect of Base Plate Removal

The precision of LPBF manufactured parts is quantified by characterizing the geometric tolerances based on the ISO 1101 standard. However, there are research gaps in the characterization of geometric tolerance of LPBF parts. A literature survey reveals three significant research gaps: (1) systematic...

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Bibliographic Details
Published in:Materials 2021-06, Vol.14 (13), p.3575
Main Authors: Rupal, Baltej Singh, Singh, Tegbir, Wolfe, Tonya, Secanell, Marc, Qureshi, Ahmed Jawad
Format: Article
Language:English
Subjects:
Additive manufacturing
Base plates
Benchmarks
Computer simulation
Design
Experimentation
Finite element method
Lasers
Literature reviews
Mathematical analysis
Powder beds
Research methodology
Simulation
Stainless steels
Tolerances
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Summary:The precision of LPBF manufactured parts is quantified by characterizing the geometric tolerances based on the ISO 1101 standard. However, there are research gaps in the characterization of geometric tolerance of LPBF parts. A literature survey reveals three significant research gaps: (1) systematic design of benchmarks for geometric tolerance characterization with minimum experimentation; (2) holistic geometric tolerance characterization in different orientations and with varying feature sizes; and (3) a comparison of results, with and without the base plate. This research article focuses on addressing these issues by systematically designing a benchmark that can characterize geometric tolerances in three principal planar directions. The designed benchmark was simulated using the finite element method, manufactured using a commercial LPBF process using stainless steel (SS 316L) powder, and the geometric tolerances were characterized. The effect of base plate removal on the geometric tolerances was quantified. Simulation and experimental results were compared to understand tolerance variations using process variations such as base plate removal, orientation, and size. The tolerance zone variations not only validate the need for systematically designed benchmarks, but also for tri-planar characterization. Simulation and experimental result comparisons provide quantitative information about the applicability of numerical simulation for geometric tolerance prediction for the LPBF process.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma14133575