Evaluation and Optimization of a Hybrid Manufacturing Process Combining Wire Arc Additive Manufacturing with Milling for the Fabrication of Stiffened Panels

Li, Fang; Chen, Shujun; Shi, Junbiao; Tian, Hongyu; Zhao, Yun

doi:10.3390/app7121233

Cited by 65 publications

(29 citation statements)

References 31 publications

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“…Because several developed DED systems include multiple powder hoppers and wire feeders to selectively supply powders and wires for different materials, the DED systems can easily fabricate a heterogeneous material with desired properties via successive and simultaneous deposition of different materials [4,32,[51][52][53][54]. Due to the simplified system of the DED apparatus as compared to the PBF apparatus, it is convenient to develop a hybrid process combining DED with different manufacturing processes [24,36,38,[55][56][57]. Hence, research and application of the DED processes has steadily increased in recent years.…”

Section: Introductionmentioning

confidence: 99%

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

318

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Metal additive manufacturing technologies, such as powder bed fusion process, directed energy deposition (DED) process, sheet lamination process, etc., are one of promising flexible manufacturing technologies due to direct fabrication characteristics of a metallic freeform with a three-dimensional shape from computer aided design data. DED processes can create an arbitrary shape on even and uneven substrates through line-by-line deposition of a metallic material. Theses DED processes can easily fabricate a heterogeneous material with desired properties and characteristics via successive and simultaneous depositions of different materials. In addition, a hybrid process combining DED with different manufacturing processes can be conveniently developed. Hence, researches on the DED processes have been steadily increased in recent years. This paper reviewed recent research trends of DED processes and their applications. Principles, key technologies and the state-of-the art related to the development of process and system, the optimization of deposition conditions and the application of DED process were discussed. Finally, future research issues and opportunities of the DED process were identified.

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Section: Introductionmentioning

confidence: 99%

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

318

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“…A considerable amount of attempts have been paid in both academia and engineering practice to determine the optimal process plan from all the alternative ones of a part; nevertheless, since meta-heuristics are the effective approaches to address NP-hard problems in engineering [15], [16], close attentions have been paid mainly to evolutional and metaheuristic based approaches in process planning optimization. For instance, Lian et al [17] proposed an imperialist competitive algorithm (ICA) in process planning optimization to minimize total weighted sum of manufacturing costs including machine cost, tool cost, machine change cost, set-up change cost and tool change cost.…”

Section: Related Workmentioning

confidence: 99%

Process Planning Optimization With Energy Consumption Reduction From a Novel Perspective: Mathematical Modeling and a Dynamic Programming-Like Heuristic Algorithm

Jin

Zhang

2019

IEEE Access

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Process planning can be deemed as an important component in manufacturing systems. It bridges the gap between designing and manufacturing by specifying the manufacturing requirements and details to convert a part from raw materials to the finished form. For the purpose of low carbon emission, this paper pays attention to both technical performance measures and environmental impact criteria. In this problem, a part may have more than one process plans and only one process plan can finally be adopted. Due to the non-deterministic polynomial-hardness, it is rather difficult to conduct operation selection, machine determination, operation sequencing, and energy consumption reduction simultaneously with various constraints from technical requirements or the shop floor status. A novel position-based mixed integer linear programming model is developed to reduce total production time and the total energy consumption. The energy consumption coefficient matrix is proposed to evaluate the energy consumption in process planning. Because of the complexity in solving the model, this research proposes dynamic programminglike heuristic algorithm to tackle this problem. The weighted sum method is applied in multi-objective optimization and three typical instances with operation flexibility, sequencing flexibility, and processing flexibility are used to test the proposed algorithm. According to the results, both the total production time and the energy consumption criteria are optimized; in the best case, the energy consumption after optimization takes only 21.2% of the one before optimization. On average, about 40.9% of the total energy consumption can be reduced after optimization. Computational results also show that the proposed algorithm is generally better than the genetic algorithm. This research gives a novel perspective to reduce energy consumption in the process planning stage. INDEX TERMS Energy consumption reduction, dynamic programming, green process planning, heuristic algorithms, operations selection & sequencing, production time minimization.

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“…The milling robot with a high-speed electric spindle ES779 (max. spindle speed is 22,000rpm) [11]. The standard cutting tool was applied by 3-flute solid carbide flat-end mill with a helix angle of 60° and a diameter of 10 mm axis.…”

Section: Introductionmentioning

confidence: 99%

Predictive Modeling of Surface Roughness Based on Response Surface Methodology after WAAM

Tian¹,

Lu²,

Li³

et al. 2019

Proceedings of the 2019 International Conference on Electronical, Mechanical and Materials Engineering (ICE2ME 2019)

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A hybrid technique of additive manufacturing and subtractive process has provided a new solution combining product design and control by software. Wire Arc Additive Manufacturing (WAAM) process wins well-respected because of its low cost and high efficiency of deposition, nevertheless the process has its limitation of high heat input and low forming accuracy. A new process of additive manufacturing with high efficiency of modeling is urgent needed which can control heat transfer, mass transfer and force transfer. To overcome the disadvantage upon, various hybrid manufacturing techniques have been developed with high efficiency and controlled modeling in recently. The machining process in hybrid manufacturing has more different characteristics from traditional material removal processes, such as residual stress and heat in the blank. These influence the whole efficiency of the hybrid manufacturing. The essential task of this paper is to explore the feasibility of thermal machining during this process and make rational use of AM in order to obtain optimal accuracy.

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Evaluation and Optimization of a Hybrid Manufacturing Process Combining Wire Arc Additive Manufacturing with Milling for the Fabrication of Stiffened Panels

Abstract: This paper proposes a hybrid manufacturing process combining wire arc additive manufacturing with milling, which provides a cost-effective and efficient way to fabricate stiffened panels that have wide applications in aviation, aerospace, and automotive industries, etc.

Cited by 65 publications

References 31 publications

Directed Energy Deposition (DED) Process: State of the Art

Directed Energy Deposition (DED) Process: State of the Art

Process Planning Optimization With Energy Consumption Reduction From a Novel Perspective: Mathematical Modeling and a Dynamic Programming-Like Heuristic Algorithm

Predictive Modeling of Surface Roughness Based on Response Surface Methodology after WAAM

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