Derek Vaughan

Mr. Derek Vaughan

Oak Ridge National Laboratory, Oak Ridge, Florida, USA

Research Focus & Metrics

Academic Career Length

7Years (2020-Present)

(Calculated once Scilit publication data is synced: current year − year of first publication + 1)

Representative Publications

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22 May 2020 in The International Journal of Advanced Manufacturing Technology
Verified
Journal Article
Closed access
PDF file
BSbishal silwal
bishal silwal
Andrzej NyczAndrzej Nycz
Andrzej Nycz
CMChris Masuo
Chris Masuo
MNMark W. Noakes
Mark W. Noakes
DMDavid Marsh
David Marsh
DVDerek Vaughan
Derek Vaughan

Verified
Journal Article
Open access
PDF file
DVDerek Vaughan
Derek Vaughan
CSChristopher Saldana
Christopher Saldana
TKThomas R. Kurfess
Thomas R. Kurfess
Andrzej NyczAndrzej Nycz
Andrzej Nycz
Thin-walled features can be difficult to produce with traditional machining methods which often rely on excess stock material for stiffness. This challenge is increased in hybrid manufacturing where the feature is already near net shape before machining. Significant workpiece deflection can result in poor geometric and surface finish tolerances on the finished part. A potential solution to this problem is to implement sacrificial support structures to the as-printed geometry. The supports are then machined away during the finishing portion of the hybrid process. In the present work, several different design parameters for these sacrificial supports were evaluated to determine their impact on the quality of representative thin wall geometry samples. The angle, height, and spacing of triangular support structures were varied for each sample and then machined and examined. The addition of these supports relative to an unsupported configuration provided a deflection reduction of around 0.2 mm. Surface roughness was improved by approximately 1.5 µm. Increasing values of support height were found to correspond to reduced wall deflection. Similarly, decreasing values of support angle and support spacing improved geometric accuracy. Efficiency comparisons showed that increases in print time corresponded to rapidly diminishing gains in geometric accuracy but continued to improve surface roughness. Implications for hybrid finishing of additively manufactured thin-walled structures is briefly discussed.