Hybrid manufacturing process planning with predictive approach: a comprehensive literature review

Abstract

The hybrid manufacturing has attracted industrial community interest due to its ability to produce functional parts with varied geometries, using different types of materials in the most varied applications. As with most manufacturing processes, before executing the hybrid process for the manufacture of a certain geometry, it is important to make a proper process planning that allows having an integral and proactive view of the operation. This work aims to synthesize through a systematic literature review (SLR) the state of the art on hybrid manufacturing process planning (HMPP) models with predictive approach. Three SLRs were developed to extract the articles of interest (2012-2022) from Science Direct, Springer Link, and Web of Science databases. PRISMA method was used to gather the papers and oriented the qualitative and quantitative analysis. Snowballing technique was used to gather articles of interest out of the period defined. Literature review showed that there is still no consensus between existing HMPP models, regarding all the activities necessary to ensure proper operation. In addition, the developed models have a limitation regarding the inclusion of a process simulation step. The simulation step on the existing models, does not allow to proactively check whether the experimental process conditions are adequate to ensure the manufacture of the modeled geometry before running the hybrid manufacturing process. An efficient simulation step would ensure a predictive approach to operation performance and would imply the reduction of geometric deviations without the need for excessive experimentation, reducing material consumption, manufacturing time, and resulting in a better deposition strategy. Using computational and statistical methods as support for decision-making in the process will allow the processing and analysis of data to assertively direct the structuring of a robust model for HMPP with predictive approach. A differentiated, more complete, and comprehensive process planning model is a relevant study opportunity for future research. This paper contributes to the theory development since it identifies and analyzes the existing HMPP models, highlights important gaps on the subject, and proposes insights for future development.