Comparative Analysis of the Dimensional Accuracy and Surface Characteristics of Gears Manufactured Using the 3D Printing (DMLS) Technique from 1.2709 Steel

This article provides a comparative analysis of the dimensional accuracy and post-surface characteristics of gears produced by the 3D printing technique Direct Metal Laser Sintering (DMLS) from 1.2709 steel immediately after printing and after grinding and grinding treatment. The following tests were performed on the fabricated samples: metallography, hardness measurement, self-stress, surface roughness, and the gears' shape were dimensioned and measured. The results show that post-processing influences the distribution of residual stress and the printed model's hardness. The results show that heat treatment results in clear directionality marks and micropores, increasing the material's hardness to 54.3 HRC ± 0.6 HRC, indicating effective strengthening. Grinding significantly improved the holes' accuracy, changed the compressive intrinsic stresses to a tensile state, and reduced radial runout, improving gear geometries. In addition, it was noted that different results were obtained for roughness parameters depending on the gear tooth tested.