Parametric Analysis for Ultrasonic-Assisted Magnetic Abrasive Finishing of AlSi12Mg Alloy Fabricated through Selective Laser Melting

The present work concentrates on the finishing of AlSi12Mg components, fabricated via selective laser melting (SLM), using a novel ultrasonic-assisted magnetic abrasive finishing process, marking its first application to 3D printed materials. The research examines the impact of varying process parameters including input voltage, rotational speed, abrasive weight percentage, abrasive grit size, and ultrasonic power intensity on surface finish (R_a), cutting force (F_c), microstructure, and residual stresses. Results indicate that increasing voltage, abrasive weight percentage, and ultrasonic power intensity enhance surface quality by reducing roughness. Rotational speed improves surface finish up to a certain limit, beyond which quality deteriorates. Finer grit sizes also contribute to better surface finishes. The optimal condition is found to be a rotational speed of 1400 rpm, a voltage of 50 V, 90% ultrasonic power intensity, 25% abrasive percentage, and 180 grit size, achieving a surface roughness of 0.179 µm, representing a 92.2% reduction from the initial SLM component. Additionally, residual stresses are increased with higher voltage, ultrasonic power intensity, and abrasive percentage, with finer grit sizes. Under these optimal conditions, a compressive residual stress of 30.3 MPa is achieved.