Applications of a hybrid manufacturing process for fabrication of metallic structures

Liou, Frank W.; Slattery, Kevin; Kinsella, Mary; Newkirk, Joseph William; Chou, Hsin-Nan; Landers, Robert G.

doi:10.1108/13552540710776188

Cited by 97 publications

(50 citation statements)

References 9 publications

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“…Liou et al (2001) and Zhang and Liou (2004) incorporated a five-axis laser cladding unit with a five-axis milling machine, where any deposition feature can be built in the horizontal direction by rotating the workstation. Thus, the need for supporting material during the deposition is eliminated, further reducing build time (Ruan et al, 2005;Liou et al, 2007). Hur et al (2002) used a five-axis CNC machine performing drilling, milling and grinding to machine laser cladded parts.…”

Section: Laser Cladding and Mechanical Machiningmentioning

confidence: 99%

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

Zhu

Dhokia

Nassehi

et al. 2013

International Journal of Computer Integrated Manufacturing

253

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Today, hybrid manufacturing technology has drawn significant interests from both academia and industry due to the capability to make products in a more efficient and productive way. Although there is no specific consensus on the definition of the term 'hybrid processes', researchers have explored a number of approaches to combine different manufacturing processes with the similar objectives of improving surface integrity, increasing material removal rate, reducing tool wear, reducing production time and extending application areas. Thus, hybrid processes open up new opportunities and applications for manufacturing various components which are not able to be produced economically by processes on their own. This review paper starts with the classification of current manufacturing processes based on processes being defined as additive, subtractive, transformative, joining and dividing. Definitions of hybrid processes from other researchers in the literature are then introduced. The major part of this paper reviews existing hybrid processes reported over the past two decades. Finally, this paper attempts to propose possible definitions of hybrid processes along with the authors' classification, followed by discussion of their developments, limitations and future research needs.

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Section: Laser Cladding and Mechanical Machiningmentioning

confidence: 99%

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

Zhu

Dhokia

Nassehi

et al. 2013

International Journal of Computer Integrated Manufacturing

253

View full text Add to dashboard Cite

show abstract

“…1 Vision of the iAtractive process production used face milling to machine each layer produced by metal inert gas welding, by which the dimensional accuracy was significantly improved. Liou et al (2007) integrated a laser cladding unit with a five-axis machining centre, where any deposition feature can be built in the horizontal direction by rotating the workstation. Kelkar and Koc (2008) developed a re-configurable moulding process where a part surface is approximated using an array of discrete and movable pins in order to create the part mould cavity.…”

Section: Introductionmentioning

confidence: 99%

A novel decision-making logic for hybrid manufacture of prismatic components based on existing parts

2014

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The on-going industrial trend towards high value sustainable manufacturing has led to the emergence of hybrid manufacturing processes. This new generation of processes combines the capabilities of a number of individual manufacturing processes on a single platform. Despite the fact that the drawbacks of individual processes have been significantly reduced, the application of hybrid technology has always been constrained by the capabilities of their constituent processes, in particular the capability to utilise various raw materials in terms of shape and size. This paper introduces a novel concept of hybrid process, which consists of combining additive, subtractive and inspection processes. A feature-based decision-making logic is developed, enabling the hybrid process to reuse existing parts/legacy products. An existing part is first measured for obtaining its geometrical information. Feasible manufacturing strategies are provided and then additive, subtractive and inspection processes are utilised interchangeably to add and/or remove material, transforming the existing part into the final part. This indicates that the iAtractive process is not restricted by raw material geometries. Three identical test parts were manufactured from three existing different shaped parts, demonstrating the efficacy of the proposed hybrid process and the decisionmaking logic in material reuse. New features can be added onto the existing parts and existing features can be removed or further manufactured, giving these parts additional lives, new uses and increased functionality.

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“…Hybrid manufacturing indicates a process, where one part is produced by two or more completely different manufacturing technologies and the advantages of each technology are used, while the disadvantages are eliminated [17]. In our case, good is to use subtractive and additive technologies on one part/product.…”

Section: Hybrid Manufacturingmentioning

confidence: 99%

The Development of a Recognition Geometry Algorithm for Hybrid – Subtractive and Additive Manufacturing

Homar¹,

Pušavec²

2017

SV-JME

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Product design is significantly dependent on its manufacturing processes. Machining, which is one of the subtractive processes, has a number of limitations related to the complexity of the product geometry [1]. Design of most products, which are to be produced by machining, is adapted to the technology itself [2].In the last decade, techniques that combine two or more manufacturing processes, such as subtractive and additive technologies, are gaining significant attention. This has resulted in many researches on the combination of subtractive and additive technologies. As a contribution to the field, in this paper an algorithm, which was developed for the purpose of being used with a hybrid manufacturing cell, is presented. The hybrid manufacturing cell was developed at institute SINTEF [3] to [5], where two manufacturing machines have been used/combined. The first machine is a Deckel-Maho 5-axis CNC milling center and the other is ConceptLaser M2 for selective laser melting of metal powders. The aim of the hybrid manufacturing cell is to automate the hybrid manufacturing process as much as possible, for the production of different products. The developed algorithm presented in this paper is a significant part of this automation chain. The desired operation of the control system in the hybrid manufacturing cell is to analyze the intended product CAD model with the mentioned algorithm and determine which parts are c be manufactured by the additive and which by the subtractive process.The first attempt to combine benefits of additive and subtractive manufacturing was the low cost integration of an arc welding unit on a 3-axis CNC milling center, presented in [6] and [7]. The main purpose of this research was to manufacture the near-net shape of the product by weld-deposition of material directly on the CNC machine table and then improve the quality of the product surface by milling. The idea is good, however, due to the rough nature of the welding process, the researched process demonstrates limited benefits of other additive manufacturing processes.Several researchers have published work on the methodology for the evaluation of manufacturing complexity for both additive and machining manufacturing [8]

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Applications of a hybrid manufacturing process for fabrication of metallic structures

Cited by 97 publications

References 9 publications

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

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

A novel decision-making logic for hybrid manufacture of prismatic components based on existing parts

The Development of a Recognition Geometry Algorithm for Hybrid – Subtractive and Additive Manufacturing

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