Abstract
Hybrid manufacturing combines additive manufacturing (AM) and subtractive manufacturing processes to achieve simultaneous benefits. Unlike traditional AM, it allows for interleaved subtractive steps, enhancing machining tool access for parts with high aspect ratios. However, optimizing the printing sequence remains as an area of exploration. In this study with two conical shapes, one exhibited a geometrical mismatch at the interface between two printing sections, while the other did not. 3D laser scanning, finite element simulation, and methodical analysis were used to understand this issue. Printing support structure before machining improved dimensional accuracy, with 0.5 mm reduction in distortion achieved, corresponding to 50 % of the final wall thickness. However, the absence of a feedback mechanism to track wall distortion after the additive process resulted in non-uniform wall thickness with a constant depth of cut during the machining operation. This research highlights the importance of process sequencing in hybrid manufacturing for achieving desired geometry.
| Original language | English |
|---|---|
| Pages (from-to) | 146-155 |
| Number of pages | 10 |
| Journal | Journal of Manufacturing Processes |
| Volume | 119 |
| DOIs | |
| State | Published - Jun 15 2024 |
Funding
This work was supported by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office (AMMTO). under contract number DE-AC05-00OR22725. The authors would like to acknowledge Prof. Sudarsanam Babu for reviewing the manuscript and valuable discussions, Dennis Brown, and Quinn Campbell for their help in experiments and data processing. Authors would like to acknowledge the cooperation and support of the Okuma Corporation and OPEN MIND Technologies USA, Inc. During the preparation of this work the author(s) used ChatGPT developed by Open AI, to improve readability and overall language. After using this tool/service, the author(s) reviewed and edited the content as needed and take(s) full responsibility for the content of the publication. No AI tool was used to analyze and draw insights from data as a part of the research process. The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper. This work was supported by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office (AMMTO). under contract number DE-AC05-00OR22725. The authors would like to acknowledge Prof. Sudarsanam Babu for reviewing the manuscript and valuable discussions, Dennis Brown, and Quinn Campbell for their help in experiments and data processing. Authors would like to acknowledge the cooperation and support of the Okuma Corporation and OPEN MIND Technologies USA, Inc.
Keywords
- Finite element method
- Geometry compliance
- Hybrid additive/subtractive manufacturing
- Interleave printing strategy
- Printing sequence