Development of an additive and subtractive hybrid manufacturing process planning strategy of planar surface for productivity and geometric accuracy

Wei-jun, Zhang; Soshi, Masakazu; Yamazaki, Kazuo

doi:10.1007/s00170-020-05733-9

Cited by 13 publications

(5 citation statements)

References 19 publications

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“…The sharp point that results in minimal CMF for a given query point x ∈ I(O, T, K, R) is thus given by: k min (x; P, T, K, R) arg min k∈K ρ CMF (x, k; P, T, R), (13) It is possible that the result is not unique, i.e., more than one sharp point exhibit the same minimal collision volume.…”

Section: Collateral Analysismentioning

confidence: 99%

“…where the arguments in t min (x) = t min (x; P, T, K, R) are dropped to simplify the notation, and the common intersection is factored out of the union. For computational purposes, it is more practical to invert the dictionary look-up from query points to the corresponding minimal-collision sharp points in (13). For a given sharp point k ∈ K, let Q(k; O, P, T, K, R) stand for the subset of all inaccessible points x ∈ I(O, T, K, R) for which k = k min (x; P, T, K, R).…”

Section: Collateral Analysismentioning

confidence: 99%

“…As a result of such impediments to HM process planning, currently practical HM use-cases are primarily restricted to short (e.g., two-step) sequences. For example, a common scenario is an AM-then-SM sequence consisting of an initial AM operation to deposit material into a "near-net" shape, followed by an SM operation intended to remove excess material (e.g., sacrificial support structures) and finish functional surfaces down to desired error tolerance and quality [12,13]. Another common scenario is an SM-then-AM sequence consisting of an initial SM operation to carve out cracked regions of a high-value part (e.g., a turbine blade), followed by an AM operation intended to fill in the removed region with new material [14,15].…”

Section: Introductionmentioning

confidence: 99%

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Hybrid Manufacturing Process Planning for Arbitrary Part and Tool Shapes

Harabin,

Behandish

2022

Preprint

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Hybrid manufacturing (HM) technologies combine additive and subtractive manufacturing (AM/SM) capabilities in multimodal process plans that leverage the strengths of each. Despite the growing interest in HM technologies, software tools for process planning have not caught up with advances in hardware and typically impose restrictions that limit the design and manufacturing engineers' ability to systematically explore the full design and process planning spaces. We present a general framework for identifying AM/SM actions that make up an HM process plan based on accessibility and support requirements, using morphological operations that allow for arbitrary part and tool geometries to be considered. To take advantage of multi-modality, we define the actions to allow for temporary excessive material deposition or removal, with an understanding that subsequent actions can correct for them, unlike the case in unimodal (AM-only or SM-only) process plans that are monotonic. We use this framework to generate a combinatorial space of valid, potentially non-monotonic, process plans for a given part of arbitrary shape, a collection of AM/SM tools of arbitrary shapes, and a set of relative rotations (fixed for each action) between them, representing build/fixturing directions on 3−axis machines. Finally, we define a simple objective function quantifying the cost of materials and operating time in terms of deposition/removal volumes and use a search algorithm to explore the exponentially large space of valid process plans to find "cost-optimal" solutions. We demonstrate the effectiveness of our method on 3D examples.

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Section: Collateral Analysismentioning

confidence: 99%

Section: Collateral Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Hybrid Manufacturing Process Planning for Arbitrary Part and Tool Shapes

Harabin,

Behandish

2022

Preprint

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“…There is difficulty creating efficient 5axis toolpath strategies and collision avoidance due to the new complex geometries (Dávila et al 2020;Jiménez et al 2021). New CAM strategies must be explored to account for accuracy with both additive and subtractive processes, which CAM software has not traditionally been designed for (Zhang et al 2020;Feldhausen et al 2022a). Tool accessibility requires much planning and design considerations.…”

Section: Introductionmentioning

confidence: 99%

Operator 4.0 for Hybrid Manufacturing

Fillingim

Feldhausen

2023

Proc. Des. Soc.

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Hybrid manufacturing, a combination of additive and subtractive manufacturing capabilities in one system, has recently become a more viable production option across several industries. Although current hybrid manufacturing research covers a broad range of topics, there is a lack of focus on how this new technology impacts both the designer and the operator of hybrid systems. This paper identifies areas of literature across design theory and Industry/Operator 4.0 research efforts and presents a path for applying this research to hybrid manufacturing users. The unique relationship between operator and designer is highlighted as they learn new strategies and develop new intuitive judgements over time to become the first experienced/expert users of hybrid manufacturing. The potential impact of excessive cognitive workload due to the novel combination of processes is discussed. This paper begins a critical discussion about proper knowledge transfer to other hybrid designers and operators, as well as towards efforts of monitoring, inspecting, and automating hybrid manufacturing processes.

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“…Another approach taken by Fuchs et al [7] involved characterization of surface waviness of AM part surfaces to determine a suitable machining tolerance for deposition geometries. Similarly, Zhang et al [8] simulated the effect of different steps over distances between beads in the construction of planar parts and used additional deposition toolpaths to correct perimeter defects. While these methods have made strides in advancing hybrid AM/SM approaches, they are either inefficient due to lack of utilization of as-built AM geometry in SM toolpath generation or they require extensive characterization experiments to implement.…”

Section: Introductionmentioning

confidence: 99%

Surface Qualification Toolpath Optimization for Hybrid Manufacturing

Thien

Saldaña

2021

JMMP

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Hybrid manufacturing machine tools have great potential to revolutionize manufacturing by combining both additive manufacturing (AM) and subtractive manufacturing (SM) processes on the same machine tool. A prominent issue that can occur when going from AM to SM is that the SM process toolpath does not account for geometric discrepancies caused by the previous AM step, which leads to increased production times and tool wear, particularly when wire-based directed energy deposition (DED) is used as the AM process. This work discusses a methodology for approximating a part’s surface topology using on-machine contact probing and formulating an optimized SM toolpath using the surface topology approximation. Three different geometric surface approximations were used: triangular, trapezoidal, and a hybrid of both. SM toolpaths were created using each geometric approximation and assessed according to three objectives: reducing total machining time, reducing surface roughness, and reducing cutting force. Different prioritization scenarios of the optimization goals were also investigated. The optimal surface approximation that yielded the most improvement in the optimization was determined to be the hybrid surface topology approximation. Furthermore, it was shown that when the machining time or cutting force optimization goals were prioritized, there was little improvement in the other optimization goals.

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Development of an additive and subtractive hybrid manufacturing process planning strategy of planar surface for productivity and geometric accuracy

Cited by 13 publications

References 19 publications

Hybrid Manufacturing Process Planning for Arbitrary Part and Tool Shapes

Hybrid Manufacturing Process Planning for Arbitrary Part and Tool Shapes

Operator 4.0 for Hybrid Manufacturing

Surface Qualification Toolpath Optimization for Hybrid Manufacturing

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