Micro-cutting mechanism of selective laser melting AlSi10Mg containing inside metal particles based on finite element analysis

Micro-cutting processes, such as single-point diamond turning, are required for selective laser melting (SLM)-fabricated AlSi10Mg to machine optical mirrors. During the SLM process, cross contamination can often introduce the different metal particle into the AlSi10Mg workpiece, inducing various surface defects (concaves and scratches) on the micro-cutting machined surface. To find the micro-cutting mechanism of SLM AlSi10Mg containing the inside metal particle, the micro-cutting process was simulated using finite element analysis (FEA). The surface morphology formation mechanisms of the SLM AlSi10Mg containing the inside metal particle during the micro-cutting process were investigated. A scratch was created on the AlSi10Mg surface when the tool was at the upper part of the inside metal particle. A concave was formed due to the entire removal of the inside metal particle when the tool acted at the lower part of the particle. The proposed model was proven efficient and accurate by verifying the above mechanism with the machined surface morphologies. This paper provides a FEA example for the micro-cutting process of alloy matrix containing the inside metal particle.