Multi-Station Multi-Axis Hybrid Layered Manufacturing (MSMA-HLM)

Karunakaran, K.P.; Gupta, Neel Kamal; Patel, Ashik Kumar; Rakeshkumar, K.; Ganesan, G.; Siddhartha, _; Sealy, Michael P.; Bernard, Alain

doi:10.1016/j.mfglet.2022.07.078

Cited by 5 publications

(3 citation statements)

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“…13d). Finally, for the first time, Karunakaran et al [114] and Gupta et al [115] integrated an interlayer cold hammering/peening system into a hybrid 3D printing machine (DED cell-laser, GTA, and GMA-and machining setup). These authors noted that hammering/peening/forging could be directly integrated into the manufacturing setup without altering it significantly; i.e., they did not need a specific manufacturing setup.…”

Section: Hammering Peening and Forgingmentioning

confidence: 99%

“…The great advantage of the hammer/peening/forging is their ability to be coupled to a robot arm or CNC machine, allowing almost unrestricted path planning and deposition strategy selection [97]. Therefore, considering the ability to be coupled to a robotic arm, the proven effect on the microstructure refinement and the improvement in the quasi-static mechanical properties, and the previous practical knowledge and performance in arc-welding, the interlayer hammer/peening/forging processes show better industrial scalability indicators, as indicated by Karunakaran et al [114] and Gupta et al [115].…”

Section: Summary and Outlooksmentioning

confidence: 99%

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Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Farias,

dos Santos,

Oliveira

2024

Int J Adv Manuf Technol

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Directed energy deposition (DED) additive manufacturing systems have been developed and optimized for typical engineering materials and operational requirements. However, parts fabricated via DED often demonstrate a diminished material response, encompassing inferior mechanical properties and heat treatment outcomes compared to traditionally manufactured components (e.g., wrought and cast materials). As a result, parts produced by DED fail to meet stringent specifications and industry requirements, such as those in the nuclear, oil and gas, and aeronautics sectors, potentially limiting the industrial scalability of DED processes. To address these challenges, systems integrating DED with interlayer (cold or hot) mechanical deformation (e.g., rolling and hammering/peening, forging) have been developed. These systems refine the microstructure, mitigate the typical crystallographic texture through static and/or dynamic recrystallization, and enhance mechanical properties and heat treatment responses without altering material specifications. In this regard, the present state-of-the-art review reports the DED + interlayer mechanical deformation systems and their variants, and their potential and limitations, providing a critical analysis to support the development and adaptation of this technology to overcome the process and material limitations that currently prevent the large-scale industrial adoption of DED processes. Furthermore, a detailed description of the grain size refinement mechanisms induced by interlayer mechanical deformation and their respective effects on the mechanical properties of commonly used 3D-printed engineering alloys (e.g., Ti-6Al-4V, Inconel 718, various low-alloy steels, AISI 316L stainless steel, and Al-based series 2xxx) is comprehensively analyzed.

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Section: Hammering Peening and Forgingmentioning

confidence: 99%

Section: Summary and Outlooksmentioning

confidence: 99%

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Farias,

dos Santos,

Oliveira

2024

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Although extensive research has been carried out on multi-axis machinery [33], methodologies and sequencing [34,35], part quality and error avoidance [36] during HM of metallic parts and multi-axis AM of various materials [37,38], very limited references can be found related to the HM of non-metallic parts. Li, Haghidhi and Yang [39] have developed and tested a multi-axis robot methodology for the HM of polymer parts, showing that it reduces production time, that parts demonstrate better surface quality after removing the staircase error, that it manufactures high quality freeform surfaces through dynamic adjustment of the tool axis direction and that it eliminates the need for support structures because of multi-axis flexibility.…”

Section: State Of the Artmentioning

confidence: 99%

Design and Analysis of a Desktop Multi-Axis Hybrid Milling-Filament Extrusion CNC Machine Tool for Non-Metallic Materials

Krimpenis

Iordanidis

2023

Machines

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Hybrid Manufacturing technologies enable the manufacturability and high manufacturing efficiency of innovative part designs comprising high complexity features which could not otherwise be manufactured in a single or a small number of steps. This study proposes the design of an industrial-grade low-cost fully automated multi-axis hybrid Additive and Subtractive CNC machine for non-metallic parts. It combines operations of a six-axis CNC machining center with a six-axis extrusion 3D printer with automated tool head change for processing parts made of polymer and special 3D printing materials (e.g., carbon fiber reinforced filaments). The design process includes static, dynamic and harmonic response Finite Element Analysis to optimize its structural strength and at the same time to reduce machine component costs down to a few thousand euros for all included components and subsystems, thus making it viable for industrial purposes. In investigated loading scenarios, analysis results show that at the brim of a 200 mm diameter round machine table, even at its most unfavorable angular positions, maximum deformation was no more than 0.24 mm, with a factor of safety in the magnitude of 10 to 20 while applying cutting force profiles with amplitudes up to 100 N, which exceedingly satisfies structural specifications for the proposed machine design operation.

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A Dual-Side Deposition Technique to Mitigate Deformation in Wire Arc Additive Manufacturing

Gupta,

Ganesan,

Siddhartha

et al. 2024

Trans Indian Inst Met

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Multi-Station Multi-Axis Hybrid Layered Manufacturing (MSMA-HLM)

Cited by 5 publications

References 0 publications

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Design and Analysis of a Desktop Multi-Axis Hybrid Milling-Filament Extrusion CNC Machine Tool for Non-Metallic Materials

A Dual-Side Deposition Technique to Mitigate Deformation in Wire Arc Additive Manufacturing

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