Geometric planning and analysis for hybrid re‐configurable molding and machining process

Kelkar, Aditya; Koç, Bahattin

doi:10.1108/13552540810841535

Cited by 13 publications

(4 citation statements)

References 16 publications

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“…Once the mold cavity is created, material is injected into the cavity and the part is removed following its solidification. Kelkar and Koc 31 developed a hybrid mold combining reconfigurable mold and multi-axis machining. This machine first builds part models in the reconfigurable mold followed by machining extra part model through multi-axis machining.…”

Section: Literature Surveymentioning

confidence: 99%

Design and development of a rapid prototyping system combining traditional fused deposition modeling and reconfigurable pins platform

Charak

Sinha

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Additive manufacturing, also commonly referred to as 3D printing, has enabled the rapid production of parts possessing complex geometry. Despite Fused Deposition Modeling (FDM) being the most popular process, it still suffers from certain limitations, such as production time and material required to build the material support structure for overhang parts. This results in increased total build time and material requirement. This article aims to eliminate these limitations by using a proposed hybrid reconfigurable pin FDM system. A hybrid system is proposed to eliminate the problem of support build time and material requirements. The proposed hybrid FDM is the combination of traditional FDM with a reconfigurable pins platform. The proposed hybrid system has been implemented for printing an overhang test part. The result analysis also reveals that the proposed hybrid system is an effective way of producing overhang parts without material support structures. A real-life case example is considered for validation of the proposed reconfigurable pins platform.

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Section: Literature Surveymentioning

confidence: 99%

Design and development of a rapid prototyping system combining traditional fused deposition modeling and reconfigurable pins platform

Charak

Sinha

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…Kelkar and Koc (2008) developed a manufacturing process that combines layer manufacturing principles in the form of rapidly re-configurable mould tooling and multi-axis machining to fabricate free-form objects. After the part is moulded, the surface accuracy is improved with final finishing operations using multi-axis machining.…”

Section: Additive and Subtractive Process Combination Assessmentmentioning

confidence: 99%

Comparative assessment of process combination for Ti6Al4V components

Conradie

Dimitrov

Oosthuizen

et al. 2017

RPJ

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Purpose The purpose of this paper is to investigate the combination of selective laser melting (SLM) and 5-axis CNC milling to produce parts from titanium powder. The aim is to achieve a more resource-efficient manufacturing process by reducing material wastage and machining time, while adhering to quality requirements. Design/methodology/approach A benchmark titanium aerospace component is manufactured with two different approaches using subtractive and additive manufacturing technologies. The first component is produced from a solid billet using only 5-axis CNC milling. The second component is grown from powder using SLM to produce a net-shaped part of which the final shape and part accuracy are achieved through 5-axis CNC milling. The potential saving of material and machining time of the process combination is evaluated by comparing it to the conventional purely CNC approach. The form accuracy, surface finish, mechanical properties and tool wear for the two processes are also compared. Findings The results show that the process combination can be used to produce Ti components that adhere to aerospace standards. With the process combination, a material saving of 87 per cent was achieved along with a reduction of 21 per cent in machining time. Further improvements are possible using optimized SLM build and machining strategies. Originality/value This paper presents the results of a resource efficiency assessment on the combination of SLM and 5-axis CNC milling for the titanium alloy, Ti6Al4V. It is expected that this process combination can make a significant contribution towards reducing material wastage and machining time for aerospace applications.

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“…Liou et al (2007) integrated a laser cladding unit with a five-axis machining centre, where any deposition feature can be built in the horizontal direction by rotating the workstation. Kelkar and Koc (2008) developed a re-configurable moulding process where a part surface is approximated using an array of discrete and movable pins in order to create the part mould cavity. After a part is moulded, multi-axis machining was conducted to improve the part accuracy.…”

Section: Introductionmentioning

confidence: 99%

A novel decision-making logic for hybrid manufacture of prismatic components based on existing parts

2014

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The on-going industrial trend towards high value sustainable manufacturing has led to the emergence of hybrid manufacturing processes. This new generation of processes combines the capabilities of a number of individual manufacturing processes on a single platform. Despite the fact that the drawbacks of individual processes have been significantly reduced, the application of hybrid technology has always been constrained by the capabilities of their constituent processes, in particular the capability to utilise various raw materials in terms of shape and size. This paper introduces a novel concept of hybrid process, which consists of combining additive, subtractive and inspection processes. A feature-based decision-making logic is developed, enabling the hybrid process to reuse existing parts/legacy products. An existing part is first measured for obtaining its geometrical information. Feasible manufacturing strategies are provided and then additive, subtractive and inspection processes are utilised interchangeably to add and/or remove material, transforming the existing part into the final part. This indicates that the iAtractive process is not restricted by raw material geometries. Three identical test parts were manufactured from three existing different shaped parts, demonstrating the efficacy of the proposed hybrid process and the decisionmaking logic in material reuse. New features can be added onto the existing parts and existing features can be removed or further manufactured, giving these parts additional lives, new uses and increased functionality.

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Geometric planning and analysis for hybrid re‐configurable molding and machining process

Cited by 13 publications

References 16 publications

Design and development of a rapid prototyping system combining traditional fused deposition modeling and reconfigurable pins platform

Design and development of a rapid prototyping system combining traditional fused deposition modeling and reconfigurable pins platform

Comparative assessment of process combination for Ti6Al4V components

A novel decision-making logic for hybrid manufacture of prismatic components based on existing parts

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