Hybrid additive and subtractive machine tools – Research and industrial developments

Abstract

By synergistically combining additive and subtractive processes within a single workstation, the relative merits of each process may be harnessed. This facilitates the manufacture of internal, overhanging and high aspect ratio features with desirable geometric accuracy and surface characteristics. The ability to work, measure and then rework material enables the reincarnation and repair of damaged, high-value components. These techniques present significant opportunities to improve material utilisation, part complexity and quality management in functional parts. The number of single platform workstations for hybrid additive and subtractive processes (WHASPs) is increasing. Many of these integrate additive directed energy deposition (DED) with subtractive CNC machining within a highly mobile multi-axis machine tool. Advanced numerical control (NC), and computer aided design (CAD), manufacture (CAM) and inspection (CAI) software capabilities help to govern the process. This research reviews and critically discusses salient published literature relating to the development of Workstations for Hybrid Additive and Subtractive Processing (WHASPs), and identifies future avenues for research and development. It reports on state-of-the-art WHASP systems, identifying key traits and research gaps. Finally, a future vision for WHASPs and other hybrid machine tools is presented based upon emerging trends and future opportunities within this research area

Hybrid manufacturing of metallic parts integrated additive and subtractive processes

“…Wynika to przynajmniej z kilku powodów [4,[12][13][14][15], w tym z możliwości: wytwarzania elementów o żądanej dokładności i jakości powierzchni; dobudowy złożonych fragmentów (np. króćców i kołnierza -rys.…”

“…Przykłady proszkowego napawania laserowego i frezowania/ /toczenia CNC (a, b) oraz naprawy łopatek (c) [7,18] stowego, bezpośredniego nakładania warstw z obróbką ubytkową), które są wyposażane w skanery laserowe 3D i urządzenia kontrolne (sondy pomiarowe 3D). Kompletny proces hybrydowy obejmuje więc: szybkościowe frezowanie (HSM), skanowanie powierzchni 3D, tworzenie modelu i podział warstw ubytku materiału, napawanie laserowe, kontrolę 3D, usuwanie zadziorów z krawędzi/ /polerowanie i znakowanie laserowe [12,21,22]. Szczegółowy opis cyklu naprawy, zaproponowany w ramach projektu RECLAIM [8,12], przedstawiono na rys.…”

Moveable Factories for Leapfrog Manufacturing in an Industrial Economy

“…There are already some examples of radical reductions in the sizes of machine tools: for example, from more than 20 cubic metres (e.g., 3 × 3 × 2.5 m) to less than two cubic metres [39,40]. Important topics include reducing the size and weight of hybrid additive and subtractive machine tools [41] and reducing uncertainty of machine tool calibration [42]. Other opportunities for increasing the range of sophisticated goods that can be manufactured locally with moveable factories may arise from technological advances, such as the Internet of Things (IoT), which can better enable Cyber-Physical Systems (CPS) that entwine digital control systems with physical operations.…”

A decision support methodology for embodiment design and process chain selection for hybrid manufacturing platforms

“…There is growing industrial and academic interest and the number of commercial hybrid additive and subtractive processes has significantly increased since the late 2000s [6]. In the papers of Zhu et al [1] and Chu et al [2], only two of the reviewed studies considered processes from more than two categories [7,8].…”