ON THE ISSUE OF DETERMINING THE EFFECTIVENESS OF FDM PRODUCT BLADE PROCESSING

Abstract

The article discusses the problem of determining the effectiveness of blade mechanical post-processing of products manufactured by additive FDM printing from thermoplastic materials. It is shown that the structure of such products is heterogeneous and hollow, with pronounced anisotropy of properties, which significantly affects the course of cutting processes and the formation of the surface layer quality. The role of post-processing as the final stage in shaping the performance characteristics of additive parts, in particular geometric accuracy, surface roughness, and the integrity of interlayer and interturn connections, is analyzed. An approach to evaluating the effectiveness of mechanical processing based on the thickness of the surface layer modification is proposed, which generalizes the changes in the stress-strain state and structural transformations of the material in the cutting wedge action zone. Analytical dependencies are given to describe the redistribution of stresses in the layered structure of FDM products, and the results of mathematical modeling of the cutting process in SolidWorks for PLA and ABS materials are presented. The influence of cutting modes on the occurrence of defects, the level of residual stresses, shape accuracy, and surface roughness parameters has been experimentally established. It has been shown that reducing the thickness of removal and feed, as well as using a sharply sharpened tool, allows to reduce the intensity of destruction of the surface layer and ensure acceptable quality of the machined surfaces. The results obtained can be used for a reasonable choice of FDM product mechanical post-processing modes.