Layer-based machining: Recent development and support structure design

Abstract

There is growing interest in additive and subtractive shaping theories that are synthesized to integrate the layered manufacturing process and material removal process. Recently, layer-based machining has emerged as a promising method for integrated additive and subtractive shaping theory. In this paper, major layer-based machining systems are reviewed and compared according to characteristics of stock layers, numerical control machining con®gurations, stacking operations, input format and raw materials. Support structure, a major issue in machining-based systems which has seldom been addressed in previous research, will be investigated in this paper with considerations of four situations:¯oating overhang, cantilever, vaulted overhang and ceiling. Except for the¯oating overhang where a support structure should not be overlooked, the necessity for support structures for the other three situations is determined by stress and de¯ection analysis. This will be demonstrated by the machining of a large castle model.

Effects of solid lubricants on wire and arc additive manufactured structures

“…AM has the ability to manufacture very complicated 3D physical geometries devoid of geometric restrictions. 1 AM can be classified into Selective Laser Sintering (SLS) also known as Powder Based Additive Manufacturing (PBAM) and Wire and Arc Additive Manufacturing (WAAM), which is Wire Based Additive Manufacturing. 2 WAAM is an aspect of additive manufacturing in which metallic components are manufactured by welding beads in a layer-by-layer manner.…”

“…4 Nevertheless, the surface of WAAM parts has a significant surface roughness in contrast to general Numerical Control (NC) machined parts owing to the WAAM process itself. 5 Researches 2,3,7,14 have investigated into the various aspects of manufacturing using Additive Manufacturing but little research has been done on the machining aspect of it. As part of the study on machining of Additive Manufacturing, Yang et al, 1 concluded that owing to the dynamic effect, Layer Based Machining (LBM) could be better used in large objects devoid of thin walls.…”

“…5 Researches 2,3,7,14 have investigated into the various aspects of manufacturing using Additive Manufacturing but little research has been done on the machining aspect of it. As part of the study on machining of Additive Manufacturing, Yang et al, 1 concluded that owing to the dynamic effect, Layer Based Machining (LBM) could be better used in large objects devoid of thin walls. However, various WAAM parts of intricate sizes have been produced with less concern for the machining especially when the surface finish is paramount to the requirements.…”

A review of hybrid manufacturing processes – state of the art and future perspectives

“…However, the magnetic field actually drives the fluid but the field does not directly work on the workpiece. Similarly, using robot(s) to hold milling cutter(s) in the machining operations (Chen and Song, 2001;Yang et al, 2002) is not considered as a hybrid process. In addition, water-jet guided laser cutting (Li et al, 2003;Kray et al, 2007), where the water-jet guides the laser beam before the beam reaches the workpiece surface, is not categorised as a hybrid process, as the jet itself does not change the microstructure of the workpiece or remove the material.…”

Automatic Tool Path Generation for Robot Integrated Surface Sculpturing System

“…Tengleder and Vergeest (4,5) were early to implement robotic arms for this purpose. Also, Chen (6,7) implemented a robotic system for sculptured surface cutting and later developed a technique that uses layer-based machining to sculpt prototypes made of polymers. In the precious research (8)(9)(10)(11)(12)(13) , a surface sculpturing system based on multi-DOF robot and shaping the 3D work-piece by heated cutting tools is proposed.…”