International Journal on Interactive Design and Manufacturing (IJIDeM) (2024) 18:1075–1085

https://doi.org/10.1007/s12008-023-01644-7

TECHNICAL ARTICLE

Influence of the aspect ratio of an additive manufacturing component

on the surface roughness during cutting with wire EDM
F. Calignano1 · V. Mercurio1

Received: 19 September 2023 / Accepted: 14 November 2023 / Published online: 13 December 2023
© The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature 2023

Abstract
Aluminum alloy AlSi10Mg is among the most used alloys in powder bed additive technologies with laser source (PBF-LB/M)
to make light components in sectors such as aerospace and automotive. These components can have complex shapes and
are made in some extrusions directly on the construction platform in order to remove them by wire electrical discharge
machining (WEDM) and obtain a surface roughness already suitable to be able to assemble the parts with other components.
This study investigated two aspects: the robustness of different instruments for profile and areal roughness measurements
on AlSi10Mg parts produced by the PBF-LB/M process; and the effect of the aspect ratio of the components on the surface
roughness obtained from WEDM. A better correspondence between the P- and S-parameters was found than that reported
in the literature between the S- and R-parameters. Analyzing the relationship between weight and height of the AlSi10Mg
components, the results showed that the heaviest and tallest component presents the least roughness (Ra  5.05 ± 0.63 µm
and Rz  33.11 ± 4.29 µm). However, it emerged that the various areas of the piece have different roughness values (from
Ra  7.65 ± 2.85 µm and Rz  43.07 ± 13.12 µm to Ra  15.21 ± 7.37 µm and Rz  68.39 ± 25.75 µm) of and this
requires constant adjustment of the cutting parameters to have uniform surface roughness.

Keywords Wire electric discharge machining · Additive manufacturing · Aluminum alloy · Aspect ratio workpiece · Surface
roughness · Laser powder bed fusion

1 Introduction the overhanging surfaces and help in the diffusion of heat

in order to reduce thermal stresses. In some cases, how-
Additive manufacturing (AM) technologies allow the pro- ever, when the geometry permits, it is possible to anchor
duction of parts with high design complexity compared the part directly to the build platform. The parts can thus be
to conventional processes [1]. Among these technologies, removed mechanically and the surfaces suitable, for example,
laser-beam powder bed fusion of metal powder (acronym for assembly with other components can be obtained. One of
PBF-LB/M according to ISO/ASTM 59,201), is becoming the most used technologies to carry out the detachment is
increasingly attractive for the aerospace, automotive and wire electrical discharge machining (WEDM). WEDM is a
medical industries [2–5]. PBF-LB/M is one of the metal spark erosion process using a fine wire electrode of cop-
additive technologies that allows, with suitably optimized per, brass or molybdenum to produce complex 2D shapes
process parameters, to produce of complex geometries with or cut with accuracy and fine surface roughness electrically
good dimensional accuracy and surface finish compared to conductive workpieces [6, 7]. As with all manufacturing
other metal additive technologies. Generally, the components processes, WEDM requires the selection of an appropriate
are built on the platform anchored by support structures set of machining parameters to achieve the desired mate-
made of the same material which are also used to hold up rial removal and surface roughness. Machine manufacturers
generally provide a machinability database to assist the user
B F. Calignano in making decisions regarding machine settings, electrode
[email protected]
wire materials to be used based on the material being cut,
1 Department of Management and Production Engineering etc. These available technological data, which are based
(DIGEP), Integrated Additive Manufacturing Center (IAM), on the manufacturer’s internal experimentation, are useful
Politecnico di Torino, Corso Duca Degli Abruzzi, 24, 10129
Turin, Italy

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but often insufficient when using new metal alloys or non-

traditional processes that generate new microstructures and
geometries with variable thicknesses. Furthermore, manu-
facturer guidelines for the selection of processing parameters
are conservative and do not always lead to optimal and cost-
effective results [8–10]. Numerous researchers have used
manufacturing process parameters to obtain a quality prod-
uct [11–14]. However, there are few studies related to the
WEDM of parts produced in PBF-LB/M and these concern
the analysis of samples generally of a parallelepiped shape a
few millimetres high. Ozaner et al. [15] investigated WEDM
parameters such as pulse on time and pulse off time to analyze
their effects on the surface integrity and mechanical charac-
teristics of specimens (starting sample sizes of 40 × 16 ×
9 mm) manufactured in PBF-LB/M/Inconel 939. Vaidyaa
et al. [16] optimized the WEDM process of PBF-LB/M -
fabricated AlSi10Mg produced cuboidal specimen (100 ×
100 × 10 mm) through a genetic algorithm approach coupled
to a hybrid artificial neural network. Taguchi’s experimental Fig. 1 Example of an RF component: a monolithic K/Ka-band dual-
design, considering the discharge current, discharge voltage circular polarization antenna-feeding network [22]
and pulse on time as input factors, is performed to obtain
results of microhardness and surface roughness. Franczyk
et al. [17] investigated the dependence of both PBF-LB/M to understand whether it is actually possible to obtain a sur-
and WEDM process parameters on process performance in face roughness suitable for the application of the component
terms of surface roughness on 7 mm high samples. The without having to carry out further processing which could
machinability of AlSi10Mg + niobium carbide (NbC) com- be complex based on the complexity of the geometry of the
posite material, based on the orientation of the pieces during component and therefore of the relative clamping. The cut-
construction with PBF-LB/M process, using the EDM pro- ting process parameters were optimized through a design of
cess was investigated by Meghanathan et al. [18]. experiments (DoE) starting from the data present in the liter-
When components are built directly attached to the build ature. In light of the widespread use of optical profile meters
platform, the WEDM cutting is performed by placing the for the analysis of surface irregularities in recent years to
platform vertically so that the wire can cut the part at the verify the specifications of the surface structure on the com-
desired distance from the build platform. In this way, the ponents made, the need has emerged to be able to make a real
piece is equivalent to a beam embedded on one side only. The comparison with the data reported in the technical drawings.
geometries also produced in PBF-LB/M are lightened at the The latter still refer to the specifications of the surface struc-
section level due to thermal stress issues during construction. ture of the profile. This has led to scientific questions on how
Also, in some industries such as satellite telecommuni- to compare the profile and areal roughness parameters [27,
cations, radio frequency (RF) engineers are increasingly 28] since the former provide information on profile texture,
moving towards building monolithic components to reduce while the latter describe surface texture in three-dimensional
issues such as increment mass, volume, and assembling com- space. For this reason, in this work, the first step was to
plexity thanks to the diffusion of AM technologies [19–22]. identify a correspondence between the primary profile (P-
These pieces can therefore come to have a narrow section parameters) and the primary surface (S- parameters).
relative to their height (Fig. 1).
To date, to the authors’ knowledge, there are various stud-
ies on the improvement of wire EDM accuracy mainly due
to wire tension [23–26] and the size of the cutting surface, 2 Materials and methods
but there are no studies on the effect of component weight on
surface roughness during the WEDM cut. Therefore, the pur- Figure 2 shows the flowchart of the research process used in
pose of this study was to analyze the effect of the aspect ratio, this study. Two aspects were investigated: the optimization
in terms of lightness and height of the component, produced of cutting parameters and the methodology for compare the
in AlSi10Mg alloy with PBF-LB/M technology on surface profile and areal roughness parameters. The results obtained
roughness after WEDM cutting. This is important in order from a first experimental plan to optimize the cutting param-
eters for the AlSi10Mg alloy and the identification of the

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Fig. 2 Flowchart of the of the research process

correct cut-off parameter for the measurement of the rough- than 0.10%. Table 1 shows the process parameters used to
ness R-parameters were the input for the evaluation of the manufacture the specimens.
effect of aspect ratio (lightness and height of the component). As can be seen from Table 1, four different sets of param-
eter values have been set: with in-skin or core, the internal
structure of the component has been created; down-skin
2.1 Sample design means the lower surfaces in contact with the platform or
support structures; with up-skin is indicate the final upper
To evaluate the influence of cantilever length and sample surfaces of the component; and finally with contour all the
weight on the roughness in the cut surface, samples with contour surfaces. This differentiation allows for improving
different shape, size and weight distribution were designed the quality of the component.
(Fig. 3). Samples were manufactured extruded onto the build
platform and rotated by 5° relative to the recoater blade to
reduce the impact zone between the part and the blade during 2.3 Wire EDM machine
the layer coating (Fig. 3c).
The experimental studies in this work were performed on a
CNC Wire Cut EDM DK7732 from Suzhou Baoma Numeri-
2.2 Production cal Control Equipment. A molybdenum wire-electrode with
a diameter of 0.18 mm was used. The temperature range of
Gas-atomized AlSi10Mg powder was used to produce the the machine tool to ensure the working accuracy is 20 °C
test specimens. The powders are stored at an ambient tem- ± 3° with a relative atmospheric humidity of 43% as per
perature of 24 °C and a relative atmospheric humidity of the manufacturer’s instructions. A first experimental plan
40% as per the manufacturer’s instructions. To produce was developed to find the best parameters in terms of sur-
PBF-LB/M/AlSi10Mg (acronym according to ISO/ASTM face roughness. Figure 5; Table 2 show the geometry of the
59,201) test specimens EOSINT M270 Dual Mode (EOS tested samples and the investigated WEDM process parame-
GmbH) system was used, equipped with a 200 W Yb-fiber ters, respectively. The current (IP) and the machining voltage
laser and a beam-spot size of 100 µm. The building platform (V m ) were set at “low” using the proprietary software of the
is heated at 100 °C to reduce thermal stresses that arise during WEDM machine. IP means the number of power tubes and
the manufacturing process. The machine works in operat- it is possible to choose a value from 1 to 6 [29]. If IP is
ing conditions at temperatures 25–30 °C with a maximum larger, the current is larger and the machining speed is faster,
relative atmospheric humidity of 45% as per the manufac- however the roughness is worse. For this reason, the lowest
turer’s instructions. The specimens were produced (Fig. 4) IP values, 1 and 2, were tested. The “low” setting for the
in an argon atmosphere to have an oxygen content of less V m means that the voltage can reach a maximum of 80 V as

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Fig. 3 a Thick andb thin samples;c samples’ position on the build platform

Table 1 Process parameters

values employed for AlSi10Mg Down-skin In-skin (core) Up-skin Contour
sample tests. Down-skin 2 layers;
up-skin 3 layers Scan speed (mm/s) 900 800 800 900
Laser power (W) 190 195 190 80
Hatching distance (mm) 0.10 0.17 0.10 –
Layer thickness (mm) 0.03 0.03 0.03

Fig. 4 Test specimens produced

reported by the manufacturer. From the literature [30, 31], it (Fig. 3) were cut 1.2 mm away from the build platform
was observed that the pulse off-time (t off ) has no significant (Fig. 6). During cutting, the wire encounters zones of dif-
impact on surface roughness. Therefore, it was been defined ferent dimensions, in particular zones a1 , a2 , a5 and a6 have
according to the manufacturer’s calculation chart based on a greater area in the x-axis than in the y-axis, whereas a3
the length of the sample to cut. However, pulse on-time (t on ) and a4 have a smaller dimension in the x-axis to the y-axis
was tested with values of 10 µs and 15 µs. The working fluid (Fig. 6b). Maintaining the nomenclature of the construction
was a JR3A emulsion solution. axes and cutting areas, the nomenclature on the surface of
The tests showed a reduction in surface roughness when the part is mirrored to the surface remaining on the platform
t on is equal to 10 µs and IP is equal to 1. Therefore, these (Fig. 6b). This is necessary to avoid interpretation errors dur-
parameters were chosen to evaluate the effect of length ing the analysis of the surface on the piece as this is rotated
and weight of the samples on roughness. Samples designed to be able to be analysed.

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Profile parameters have a mathematical expression that

can easily be extended to surfaces. For example, the Sa equa-
tion is the areal extrapolation of the Ra (arithmetic mean
deviation) equation (Eq. 1):

 l ¨
1 1
Ra  |Z (x)|d x Sa  |Z (x, y)|d xd y (1)
l 0 A
A

Sq, Ssk, Sku, Sp, Sv, etc. can therefore be defined straight-
forwardly in the same way. Parameter equations use integrals
instead of sums because they represent the definition for con-
Fig. 5 Geometry of the samples used to optimize the cutting parameters tinuous case.
The range of variability of the S-parameters was estimated
and used to identify the appropriate roughness sampling
Table 2 WEDM process parameters tested in the first experimental plan length (cut-off length). The P- and S-parameters were com-
Parameters Value
pared leading to a better match than that between the R-
and S-parameters. Two different tools were used to esti-
Pulse on-time, t on (µs) 10, 15 mate the areal roughness parameters, a 3D optical scanner
Power-tube number, IP 1, 2 with its 3D analysis software and surface analysis and
Voltage, V m ≤ 80 V metrology software. A profilometer was used to estimate
the roughness profile parameters. ISO 25178-2 gives some
examples of methods for areal topography measurements
that include a structured light projection. As indicated by
2.4 Surface roughness
the same international standard, each method used to mea-
sure surface roughness, whether they are line-profiling or
Starting from what is reported in the respective regulations
area-topography, has range and resolution limits both in lat-
(ISO 21920-2:2022, ISO 25178-2), it is possible to find a
eral and vertical directions. The following tools were used to
correspondence between the primary profile (P-parameters)
evaluate the roughness:
and the primary surface (S-parameters). This allows for sub-
sequently tracing the correct cut-off to use instead of carrying
out several tests as described in the standard before arriving • SM Metrology Systems RPT80 tester with a diamond sty-
at the correct value. lus of a radius of 2 µm, resolution of 0.001 µm and an

Fig. 6 a Cutting direction with respect to manufactured direction;b position of the platform during cutting and nomenclature of cutting surfaces

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Fig. 7 Profile trace according to ISO 21920-2:2022

Fig. 8 Color map of sample 1: surfaces obtained witha GOM Inspect
accuracy class of 1° according to ISO/DIN with a maxi- andb MountainsMap
mum permissible error of 5%.
• Atos Compact Scan 2 M by GOM GmbH, a 3D optical
scanner with a resolution of 2MP and accuracy within parameters on the primary profile (P-parameters) were eval-
the expected measurement specifications according to uated using a profilometer and compared with the primary
VDI/VDE 2634, Part 3, with the probing error form (PF) of surface (S-parameters).
0.001 mm, probing error size (PS) of − 0.004 mm, sphere For the areal surface texture method, the maximum of the
spacing error (SD) of − 0.004 mm and length measure- deviations was assumed as the maximum value of the peak
ment error (E) of 0.016 mm. height Sp, the minimum as the maximum value of the depth
• MountainsMap software by Digital Surf. The software is of the well Sv, consequently Sz turns out to be the sum of the
compliant with ISO 25,178 standards. maximum and the minimum, and finally, the standard devia-
tion of the heights on all points of the geometry was defined as
Three cubic samples in AlSi10Mg produced by the mean squared height parameter Sq. The areal parameters
PBF/LB/M with side dimensions of 10 mm were used. The have been used to evaluate the roughness sampling length.
up-skin surfaces of the samples were scanned and the areal The variability range of Pq, Pp and Pv parameters has been
roughness measurements were performed using two differ- identified. Pz represents the sum of the largest peak height
ent methodologies: one based on fitting elements (with GOM and the largest pit depth of the primary profile along the sam-
Inspect software) and the other with surface analysis software pling length, whereas Pt is the same measurement but along
(MountainsMap). The up-skin surfaces were analyzed as they the evaluation length. Pz values are not available on some
present a higher surface and non-periodic roughness com- commercial profilometers, thus Pt has been assumed to be
pared to the roughness obtainable through WEDM. In this equal to Sz.
way, the worst condition with the possibility of reflectivity From the results shown in Table 3, it is evident that both
problems due to the greater surface roughness was analysed methods (best-fit analysis and metrology software) lead to
to evaluate the goodness of the instrumentation used. comparable results with a mean percentage difference of 6%.
As required by ISO 21920-2:2022, the profile trace was Figure 8 shows the color maps for the two methods used.
detected as an intersection of the leather model with an inter- The histogram of the legends highlights the distribution of
section plane perpendicular to it and in a specified direction irregularities on the surface: the red areas are classified as
(Fig. 7). hilly regions, while the blue areas are valley regions. Both
analyses lead to the same chromatic map highlighting the
same distribution of points on the reference surface. For the
3 Results and discussion results obtained, the best-fit method was used for the areal
surface roughness analysis of the WEDM cut specimens.
3.1 Surface roughness measurement The S-parameters have been related to the correspondent
parameters of the primary profile. In some cases there is an
For roughness profiles, ISO 21920-2:2022 requires an initial average percentage difference between profile measures and
estimate of the roughness profile parameters by visual or sur- previous analysis of about 20%: it can occur because the lines
face inspection to select an adequate cut length. Therefore, travelled by the probe can be characterized by more peaks or
the areal surface texture method was used as a preliminary more pits.
analysis to observe the distribution of defects on the surface, The Pt parameter thus makes it possible to go back to the
identify the range of data variability and select the appropri- setting class according to ISO 21920-3:2022 and obtain the
ate cut length for profile measurements. Then, the roughness correct evaluation length.

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Table 3 Comparison between primary surface and primary profile measurements

Roughness parameters Best-fit analysis Metrology software Primary profile analysis

Sample 1 As-built (µm) Shot-blasted As-built (µm) Shot-blasted As-built Shot-blasted

(µm) (µm) (µm) (µm)
Sq or Pq 42 27 40.4 26.2 49.3 (0.62) 29.5 (1.64)
Sp or Pp 135 95.5 129.6 94 129.1 (5.23) 67.1 (16.44)
Sv or Pv 155 142.5 149.2 137.9 119.9 (7.33) 87.9 (11.01)
St or Pt 290 238 278.9 231.9 249 (4.05) 155 (7.48)
Sample 2 As-built (µm) Shot-blasted As-built (µm) Shot-blasted As-built Shot-blasted
(µm) (µm) (µm) (µm)
Sq or Pq 48.04 30.7 45.7 30.8 58.89 (3.53) 35.4 (3.26)
Sp or Pp 158.3 98.8 163.4 98.8 131.6 (7.88) 85.6 (5.35)
Sv or Pv 197 146.2 244.6 180.9 159.5 (3.74) 107.1 (12.44)
St or Pt 355.2 245 408 279.7 291.1 (10.64) 192.6 (7.41)
Sample 3 As-built (µm) Shot-blasted As-built (µm) Shot-blasted As-built Shot-blasted
(µm) (µm) (µm) (µm)
Sq or Pq 51.8 33.1 50.3 32.1 52.9 (3.34) 40 (2.96)
Sp or Pp 151.2 90.6 152.9 86.3 132.5 (23.11) 77.7 (0.39)
Sv or Pv 197.8 168.4 215.1 187.2 145.6 (12.27) 116.6 (8.87)
St or Pt 349 259 368 273.5 278.2 (30.43) 194.4 (8.83)

Standard deviation in parentheses

3.2 Effect of the aspect ratio on roughness are area on the surface (zone), height (A) and weight (weight);
the interaction plot (Fig. 10b) visualizes how the relationship
Table 4 and Fig. 9 show the areal roughness results: it can between one variable and roughness depends on the value of
be deduced that S3 has a greater roughness localized in area a second variable. Figure 10c shows the 3D surface plot from
a4 . This leads to thinking that the greater length and greater which it can be seen how the roughness variable relates to the
weight result in worse surface roughness on half of the sur- two variables height and weight. The peaks and valleys cor-
face. Observing the Gaussian distribution of Fig. 9, it can be respond to combinations of heights and weights that produce
seen that it is very close in samples S2 and S4 while it has a local maxima and minima, respectively.
slightly larger amplitude in samples S1 and S3 As evidenced by the surface analysis, zones a3 and a4 are
The range of S-parameters suggests using a cut-off of those in which there is a greater variation in the roughness
8 mm which by standard implies an evaluation length of trend. In general, looking at the main plot (Fig. 10a), the taller
40 mm considering the number of sections equal to 5. When samples show a lower roughness and, except in the case of
looking at the six zones within the part surface, there is not the component with a weight of 77 g, the roughness of the
enough space in all areas to carry out measurements. By mak- heavier samples is almost similar to the roughness of the
ing a comparison between the measurements carried out with sample lighter. Observing the interaction between zone and
the evaluation length and five individual sampling lengths height (Fig. 10b), it can be seen that the lowest samples in
along the evaluation length, in the first case, the profilometer addition to having a higher average roughness, show a sudden
averaged the measurements of the single sampling lengths. increase in roughness passing from zone a2 to zone a3 and a
Consequently, even if there is not enough area on the surface sudden decrease from zone a4 to zone a5 . In the case of the
to be analysed to cover the total evaluation length, it is suf- highest samples, there is no sudden variation of roughness
ficient to perform several measurements with the sampling in those areas but there is a greater roughness in area a4 as
length and reach the total evaluation length. Table 5 shows evidenced by the areal roughness. Analyzing the relationship
the results in terms of Ra and Rz. between weight and height (Fig. 10c), it is evident that the
Compared to the analysis of areal surface roughness, the heaviest and tallest component (S3) has the lowest roughness.
results allow for a more in-depth analysis of the effect of This is mainly due to if the component is considered as a beam
height and weight during cutting. Figure 10 shows the factor blocked only at one end, the higher and heavier it is, the more
plots. The main effects plot (Fig. 10a) shows the relationship it will tend to open, also due to the force of gravity which
between surface roughness and the individual variables, that adds up to the weight, as the electrode advances thus leading

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Table 4 Areal surface roughness

values Samples Sq (µm) Sp (µm) Sv (µm) St (µm)

S1 31.58 113.82 278.48 392.30

S2 32.22 113.37 317.78 431.15
S3 38.80 236.79 266.08 502.87
S4 32.66 50.53 271.24 321.77

Fig. 9 Color map of surfaces

with Gaussian distribution

to the creation of a gap which improves the surface roughness However, it is interesting to note that the profile roughness
(Fig. 11). Since the component is built with an inclination of measurements bring out the effect of the aspect ratio on the
5°, the opening of the component will be incremental and final roughness of the component more clearly than the areal
not clear on the final length of the surface. The zone a4 has roughness measurements. In fact, with the same cutting sur-
a greater roughness because the sample, while it opens more face, the S1 component has a greater roughness than the S3
from the top, in the lower area will tend to close, reducing component probably because the protrusion effect (height)
the gap and therefore worsening the roughness. added to the gravity and weight in the S1 sample is lower
The variable surface that can be found in a piece man- than in the case of the S3 sample. Sample S4 also has a lower
ufactured with PBF-LB/M technologies implies the need roughness than sample S2, highlighting the positive effect
for a constant adjustment of the parameters to arrive at a due to the height with the same cut surface.
more uniform surface roughness on the surface of the piece.

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Table 5 Results of the profile surface roughness

Samples a1 a2 a3 a4 a5 a6

Ra Rz Ra Rz Ra Rz Ra Rz Ra Rz Ra Rz

S1 11.34 60.79 10.66 54.56 18.05 81.09 19.23 85.34 10.45 55.69 10.32 56.68
(0.41) (4.94) (0.67) (2.08) (0.16) (2.42) (0.84) (1.99) (0.47) (4.17) (0.49) (6.51)
S2 9.17 51.77 9.68 53.94 19.54 83.24 21.99 90.25 9.37 50.64 10.48 55.95
(0.30) (1.69) (0.36) (0.64) (0.71) (6.52) (0.63) (2.88) (0.43) (2.85) (0.57) (2.17)
S3 4.68 30.28 5.02 34.81 5.48 36.11 5.20 33.65 4.07 26.04 5.90 37.78
(0.25) (3.41) (0.50) (4.26) (0.20) (1.49) (0.16) (3.79) (0.38) (1.09) (0.03) (1.13)
S4 7.92 43.00 8.74 48.20 8.27 45.07 14.44 64.31 6.73 39.90 5.22 35.42
(0.14) (1.49) (0.37) (2.27) (0.44) (1.82) (0.88) (4.11) (0.54) (5.20) (0.15) (3.84)

The values are in (µm). The standard deviation is indicated in parentheses

Fig. 10 a Main effects plot,b interaction plot, andc surface plot for Ra and Rz

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Fig. 11 Diagram of the rotation of the S3 and S4 samples during cutting

4 Conclusion • The surface of a PBF-LB/M component can present

variable sections which imply the need for a constant
The study focused on two aspects: the first concerned the pos- adjustment of the parameters to arrive at a more uniform
sibility of comparing the area and the profile of the roughness surface roughness on the surface of the piece;
with different tools (one based on fitting elements, a metrol- • Profile roughness measurements show more effect of the
ogy software (e.g.MountainsMap) and a profilometer), and aspect ratio on the final roughness of the component than
the second was the effect of the aspect ratio on the roughness areal roughness measurements.
obtained by cutting using WEDM of pieces made with an
additive process. The following conclusions can be deduced:
Acknowledgements Vincenza Mercurio is funded by a PhD scholar-
ship from the PON Research and Innovation 2014–2020 “Education
• The two methods tested for areal surface analysis (best- and research for recovery - REACT-EU” according to the Ministerial
Decree of August 10, 2021, no. 1061.
fit analysis and metrology software) led to similar results
with a percentage difference of about 6%; Author contribution FC: Supervision, Conceptualization, Methodol-
• From areal surface texture analysis, it was possible to iden- ogy, Investigation, Validation, Formal analysis, Writing—original draft
tify the zones with more defects and the cut-off length for preparation. VM: Formal analysis, Investigation, Validation, Writing -
original draft preparation.
profile measurements;
• It is possible to use the sampling length as evaluation length
Declarations
for profile roughness measures;
• A better correlation has been found between S- and P- Conflict of interest The authors declare that they have no known com-
parameters, instead of the main reported in the literature peting financial interests or personal relationships that could have
between S- and R- parameters; appeared to influence the work reported in this paper.
• Analyzing the samples with the same cutting length, due
to the force understood as the sum of the weight of the
object itself and gravity, the taller and heavier components References
show better surface roughness considering R-parameters
(S3: Ra  5.05 µm ± 0.63 µm and Rz  33.11 µm ± 1. Gibson, I., Rosen, D.W., Stucker, B.: Additive Manufacturing Tech-
nologies. Springer (2010). (2014)
4.29 µm). In contrast, the lightest and lowest component 2. Calignano, F., Manfredi, D., Ambrosio, E.P., Biamino, S., Lom-
(S2) has the highest roughness (Ra  13.37 µm ± 5.8 µm bardi, M., Atzeni, E., Salmi, A., Minetola, P., Iuliano, L.,
and Rz  64.30 µm ± 17.62 µm); Fino, P.: Overview on additive manufacturing technologies. Proc.

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19. Calignano, F., Peverini, O.A., Addamo, G., Iuliano, L.: Accuracy author(s) or other rightsholder(s); author self-archiving of the accepted
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