Work

Towards Sustainable Manufacturing: Particle Emissions in Milling Post-Processing of 3D-Printed Titanium Alloy

Year: 2025

Type: article

Abstract: Electron beam melting (EBM) is an additive manufacturing method that enables the manufacturing of metallic parts. EBM-printed parts require post-processing to meet the surface quality and dimensional accuracy requirements. Machining is one approach that is beneficial for achieving these requirements. However, during machining, particles are emitted and can affect the environment and the operator’s health. This study aims to investigate the concentration of particles emitted during the milling of 3D-printed Ti6Al4V alloy produced by EBM. First, the influence of machining speed and cutting fluids, namely flood and minimum quantity lubricant (MQL), on particle emissions was statistically investigated. Then, the standby time required for the operator to safely open the machine door and interact with the machine within the machining area was studied. In this regard, two scenarios were proposed. In the first scenario, the machine door is open immediately after machining, and the operator waits until the particle concentration is acceptable. In the second, the machine door will be opened only when the particle concentration is acceptable. Statistical findings revealed that cutting fluids have a significant impact on particle emissions, exhibiting distinct patterns for both fine and coarse particles. Irrespective of the scenario, MQL results in higher particle concentration peaks and larger particle sizes, and the operator needs a longer standby time before interacting with the machine. For instance, the standby time in MQL is 328% more than that of the flood system. This study provides insight into sustainable manufacturing by taking into account social factors such as worker health and safety.

Source: Machines

DOI: 10.3390/machines13111051

Authors: Fahad M. Alqahtani, Mustafa Saleh, Abdelaty E. Abdelgawad, Ibrahim A. Almuhaidib, Faisal Alessa

Institution: King Saud University

Language: English

Topic: Advanced machining processes and optimization

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Responsible consumption and production

Open Access status: gold

Estimated APC paid: $2,896