An Effect of DMLS Process Parameter on Surface Roughness And Dimensional Accuracy Of CL50WS Material

Direct metal laser sintering (DMLS) process used to make three-dimensional product or joining two elements without any tooling or human intervention from computer aided data (CAD) file. CL50WS material is hot work tool steel which widely used to make die and mould in tooling industries. DMLS widely accepted to manufactured die, mould and tooling insert in tooling industries. It can be made customized tooling insert, die and mould with cooling channel which is also known as conformal cooling. Die, mould or tooling insert are widely used in injection moulding industries which manufacture mass production of discrete parts for assembly or as final product. Thus, worse dimensional accuracy and surface roughness of die and mould affect number of parts or products that make huge losses to industries. Thus, dimensional accuracy and surface roughness of die or mould is very significant parameter for injection moulding industries. Hence, this study carried out for the same. In this study, the relationship between input parameters of DMLS (laser power, layer thickness, scan speed and hatch distance) and performance characteristic (Dimensional accuracy and Surface roughness) have been discussed. From study, it can be seen that Layer thickness and laser power are most affective parameter for mentioned characteristic. Empirical model for both characteristics have been developed for future prediction of DA and SR at outside range of process parameter. Optimum result has been determined by Response Surface methodology (RSM). The obtained result was validated and that optimum result have good agreement with performed regression result.