Integrated Process Planning for a Multiaxis Hybrid Manufacturing System

Abstract

A hybrid manufacturing system integrates computer numerical controlled (CNC) machining process and layered deposition process and achieves the benefits of both processes. An integrated process planning framework, which includes every module of the hybrid manufacturing process is critical for making the building of functional parts feasible and reliable. In this paper, the hybrid manufacturing system is introduced and the integrated process planning framework, which aims to automate the hybrid manufacturing is investigated. Critical components of the process planning, including decomposition of the computer-aided design (CAD) model, improvement of the toolpath generation pattern, and collision detection algorithms, are discussed. The interfacing and integrating process between deposition and surface finish machining is also studied. The goal of integrated process planning is to realize the automatic hybrid manufacturing process without much human interference. Experiments are implemented to validate the feasibility and reliability of the integrated process planning framework.

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

“…Although the designer is supported in the analysis of a 3D CAD product design, the presented method cannot be used to support the translation of a concept design into that initial 3D CAD model. This limitation also exists for the methodologies A decision-support methodology for embodiment design and process chain selection for hybrid manufacturing platforms 5 of Ren et al [17] and Zhu et al [18], which similarly require the input of a 3D CAD model to enable analysis of a detailed design as opposed to supporting the early design stages.…”

“…Ren et al [17] developed an integrated process planning framework for hybrid manufacturing with additive and subtractive processes (direct metal deposition and CNC machining). Similarly, Zhu et al [18] presented a process planning method for a hybrid additive and subtractive system (fused deposition modelling and CNC machining).…”

Hybrid Manufacturing System Design and Development

“…Adaptive multi-axis slicing, collision detection, and adaptive tool path pattern generation for LMD as well as tool path generation for surface machining are the key advantages to the integrated process planning software developed for the LAMP hybrid system (Ren et al, 2010).…”

“…Collision detection is implemented by Boolean operation, which is an intersection operation, on a simulation (Ren et al, 2010). If the intersection result of the updated CAD model and the cladding head nozzle is not empty, then collision will happen in the real deposition process.…”

“…The objective of the process planning software is to integrate the five-axis motion and deposition-machining hybrid processes. The results consist of the subpart information and the build/machining sequence (Ren et al, 2010;Ruan et al, 2005). To generate an accurate machine tool path a part skeleton, which calculates distance and offset edges or boundaries, is created of the CAD model.…”