Investigation of manufacturability and efficiency of micro channels with different geometries produced by direct metal laser sintering

Cemal İrfan Çalışkan*, Mert Coşkun, Gökhan Özer, Ebubekir Koç, Turgut Azer Vurkır, Gökay Yöndem

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

14 Citations (Scopus)

Abstract

Manufacturability without supports in design studies for additive manufacturing (AM) brings many advantages such as time, cost, part surface quality, and design freedom. It is thought that the geometries that can be produced without support will help the more widespread use of AM technologies. In this study, the unsupported manufacturability and efficiency research of conformal cooling channel (CCC) geometries created in cylindrical, wide oval, drop, hexagonal, narrow oval, and pentagonal cross-sections were conducted in the direct metal laser sintering (DMLS) system. The study offers innovation in terms of showing the usability of different channel geometries in CCC applications. The study shows that the pentagon form has the most efficient cooling capacity among the comparatively handled geometries. The results are obtained by a computational fluid dynamics (CFD) analysis study on computer-aided design (CAD) data of the actual state channel geometry obtained by CAD and post-production micro-CT scanning of the design and presented in tables. This research shows that the production-induced sagging problem affects the flow by narrowing the channel hydraulic diameter in channel geometries produced without CCC supports.

Original languageEnglish
Pages (from-to)3805-3817
Number of pages13
JournalInternational Journal of Advanced Manufacturing Technology
Volume117
Issue number11-12
DOIs
Publication statusPublished - Dec 2021
Externally publishedYes

Bibliographical note

Publisher Copyright:
© 2021, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.

Keywords

  • Additive manufacturing
  • Conformal cooling channels
  • Direct metal laser sintering
  • Microchannels

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