Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers

Round 1

Reviewer 1 Report

Comments and Suggestions for Authors

Congratulations to the authors for their work. The article is interesting and has good potential! In my opinion, there are a few aspects that need to be improved:

1. The introduction is too general - there is no reference / comparison between what exists and what this article wants to present / do;

2. Cyrillic characters appear in tables 2 and 3;

3. Fig. 2 - The quality of the images must be improved - the notations of the forces are not understood;

4. For when calculating the forces that appear in the cutting process, don't you also have to take into account the geometry of the tool?

5. Where the constraints and fixing surfaces for the tool are represented?

6. What influence does changing the shape of the cooling channels have on the resistance of the tool?

7. Figures 3, 5, 6 and 7 - It would be good to keep the same colors to present the surfaces you are referring to (eg green for surfaces and blue for the body of the tool);

8. Fig. 8 - Image (b) is not clear - please find another viewing point. Why is there a need for unchanged surfaces because I saw that you exclude the entire tip of the tool?

9. Fig. 10 - The image of the whole assembly is not clear - please find another way of presentation.

10. Fig. 11 - It would have been useful to present several images and one, through transparency, to contain all the surfaces presented above!

11. Fig. 12 - Cum este aplicata forta? Punctual sau pe suprafata?

12. Figures 13 and 14 - How does the behavior of the tool influence the change of the center of gravity?

13. What is the scientific value that you bring by presenting the operation of the metal polymer filling installation? Is the installation designed by you?

14. Can you present what a tool/part looks like in which you have inserted metal polymer?

15. Have you done a simulation for the tool designed above to take into account the filler material (metal polymer)?

Author Response

Please see the attachment

Author Response File: Author Response.pdf

Reviewer 2 Report

Comments and Suggestions for Authors

In this manuscript, technology for manufacturing a metal-composite structure of a metal-cutting tool body is described. The finite element calculations are provided with a particular emphasis on the justification of selected loads on the tool body arising from metal cutting forces. The methodology for designing a model of a tool body ensures the reduced material weight/volume: a thin-walled outer shell is produced that forms the external drill body while the technology for filling internal cavities with a viscous metal-polymer is also explained. Finally, it is claimed that the suggested design can reduce the volume of 3D metal printing by ~32%, which amounts to >$135.

Issues that need to be addressed:

1.       Only modeling aspect is covered with a special emphasis on the reduction in volume and weight. However, data on the variation in the strength of the tool is not provided. The performance of the tool should be considered in relation to reduced size and weight. Quantitative data on the weight and volume reduction is provided but no data on the strength variation is given? With the modification is design, what is the variation in the strength?

2.       Concise conclusions are not provided separately at the end of the manuscript.

3.       What unique properties are provided by the filling materials, i.e. metal-polymer compositions. And why the percentage of composition is 8-20. Please mention and explain.

4.       Do you think that minimum safety margin value of 1.2 will work OR otherwise?

5.       The acquired strength of metal-polymer material has not been considered due to the complexity of constructing a computational model. How much does it affect the results?

6.       Laboratory vibration-vacuum installation for implementing a method for manufacturing metal-composite products is shown in Figure 16. Have authors produced any product? If yes, present it in the manuscript.

7.       Table 4 should also provide the mechanical properties of the mutually compared designs in addition to weight and cost.

8.       The drill body does not experience significant thermal stress during the cutting process since effective cooling of the cutting zone is ensured. Is it expected or you have experimental evidence.

9.       Please provide evidence of the manufacturers, which achieve dampening of the tool’s vibrations after filling the internal cavities with molten metal. Moreover, molten metal remains molten or only melts during the operation of the tool. Kindly explain.

Suggestions:

You mentioned “ergonomics” in the “Introduction” but did not relate your research with it.

If you write an abbreviation in your article, first write it completely unless an abbreviation is universally accepted, i.e. SLM.

Please refer and cite more articles in “Introduction” relate to your research work to allow the readers to have an idea of the status of research work in this field? Although it is not a review article, a comprehensive introduction is still required.

Clearly mention if the idea you are presenting (metal-composite body) is not available in literature. In case, it is available, what improvements have you done?

In the last paragraph of “Introduction” briefly explain what you have done in this research work than writing a general comment.

Please provide references for the data given in Tables 1, 2 and 3.

Comments on the Quality of English Language

Minor editing of English language required.

Author Response

Please see the attachment

Author Response File: Author Response.pdf

Round 2

Reviewer 1 Report

Comments and Suggestions for Authors

Congratulations to the authors for their comprehensive and interesting work!

Reviewer 2 Report

Comments and Suggestions for Authors

Dear authors, thank you for your response to the issues and suggestions regarding your submitted manuscript.

Comments on the Quality of English Language

Minor editing of the Engligh language is required, which will be done by the Journal.