Development of a modular computer-aided process planning (CAPP) system for additive-subtractive hybrid manufacturing of pockets, holes, and flat surfaces

Basinger, Katie L.; Keough, Carter; Webster, Caroline E.; Wysk, Richard A.; Martin, Thomas M.; Harrysson, Ola L. A.

doi:10.1007/s00170-018-1674-x

Cited by 27 publications

(19 citation statements)

References 17 publications

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“…Having parts in the micro/nano-scale requires precision machines that are accurately controlled by computers [10]. However, based on the literature, as yet, the best results are achieved out of hybrid manufacturing processes that are a combination of additive and subtractive processes [83]. These processes can take place either concurrently or in sequence to complete the required task from the machines and there is no limitation on the number of processes utilized in order to produce the 3D object.…”

Section: Hybrid Additive Manufacturing In Micro/nano-scalementioning

confidence: 99%

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

et al. 2019

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Additive manufacturing (AM) or three-dimensional (3D) printing has introduced a novel production method in design, manufacturing, and distribution to end-users. This technology has provided great freedom in design for creating complex components, highly customizable products, and efficient waste minimization. The last industrial revolution, namely industry 4.0, employs the integration of smart manufacturing systems and developed information technologies. Accordingly, AM plays a principal role in industry 4.0 thanks to numerous benefits, such as time and material saving, rapid prototyping, high efficiency, and decentralized production methods. This review paper is to organize a comprehensive study on AM technology and present the latest achievements and industrial applications. Besides that, this paper investigates the sustainability dimensions of the AM process and the added values in economic, social, and environment sections. Finally, the paper concludes by pointing out the future trend of AM in technology, applications, and materials aspects that have the potential to come up with new ideas for the future of AM explorations.

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Section: Hybrid Additive Manufacturing In Micro/nano-scalementioning

confidence: 99%

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

et al. 2019

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“…Priarone et al [15] have proposed a modelling framework for the assessment of hybrid manufacturing applicability, using WAAM and machining, over conventional subtractive processes, and the benefit in terms of cost, cycle time, energy consumption, and environmental impact. Basinger et al [16] have proposed a feature-based process planning method, aiming to create semi-automatic and automatic operation sequencing plans for hybrid manufacturing processes, focusing on the reduction of manufacturing time. In the same principle, Liu et al [17] have developed an operation sequencing algorithm for five-axis hybrid manufacturing of complex parts, taking into account tool accessibility and focusing on the reduction of the necessary tool changes.…”

Section: Literature Reviewmentioning

confidence: 99%

Hybrid subtractive–additive manufacturing processes for high value-added metal components

Stavropoulos

Bikas

Avram

et al. 2020

Int J Adv Manuf Technol

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Hybrid process chains lack structured decision-making tools to support advanced manufacturing strategies, consisting of a simulation-enhanced sequencing and planning of additive and subtractive processes. The paper sets out a method aiming at identifying an optimal process window for additive manufacturing, while considering its integration with conventional technologies, starting from part inspection as a built-in functionality, quantifying geometrical and dimensional part deviations, and triggering an effective hybrid process recipe. The method is demonstrated on a hybrid manufacturing scenario, by dynamically sequencing laser deposition (DLM) and subtraction (milling), triggered by intermediate inspection steps to ensure consistent growth of a part.

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“…The Feature-based Advanced Hybrid Manufacturing Process Planning System (FAH-PS) presented by [19] may be applied to multiple types of hybrid manufacturing processes such as casting-, injection molding-, and additivesubtractive. FAH-PS utilizes a modular and extensible software framework, which was intended to address: (1) the determination of operations final order in a process plan, (2) the types of processes supported in a hybrid process plan for holes, flats and slot features, and (3) the general extensibility of process planning systems for future program advancements [19]. The decision structure of FAH-PS uses feature specific geometric, tolerance, and material data inputs to generate automated process plans based on a user-specified critical feature precedence [19].…”

Section: Feature-based Advanced Hybrid Manufacturing Process Planning System (Fah-ps)mentioning

confidence: 99%

“…FAH-PS utilizes a modular and extensible software framework, which was intended to address: (1) the determination of operations final order in a process plan, (2) the types of processes supported in a hybrid process plan for holes, flats and slot features, and (3) the general extensibility of process planning systems for future program advancements [19]. The decision structure of FAH-PS uses feature specific geometric, tolerance, and material data inputs to generate automated process plans based on a user-specified critical feature precedence [19]. Individual modules are used to process machine information about specific feature types (hole, pocket, slot, etc.)…”

Section: Feature-based Advanced Hybrid Manufacturing Process Planning System (Fah-ps)mentioning

confidence: 99%

Advanced Manufacturing Using Linked Processes: Hybrid Manufacturing

Basinger¹,

Webster²,

Keough³

et al. 2020

Mass Production Processes

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Hybrid Manufacturing Processes (HMP) can significantly reduce time to customer, waste, and tooling costs per part, while increasing possible part geometric complexity for small batch parts. In the following chapter, HMP is defined by the production of parts produced first with a near-net shape process using methods including: additive manufacturing, casting, injection molding, etc., which is then coupled with multi-axis computer numerical control (CNC) subtractive machining or some other secondary material removal process. Creating process plans for such hybrid manufacturing processes typically takes weeks rather than hours or days. This chapter outlines several hybrid manufacturing processes and the intricacies required to develop process plans for these complex linked processes. A featurebased advanced hybrid manufacturing process planning system (FAH-PS) uses feature-specific geometric, tolerance, and material data inputs to generate automated process plans based on user-specified feature precedence for additivesubtractive hybrid manufacturing. Plans generated by FAH-PS can optimize process plans to minimize tool changes, orientation changes, etc., to improve process times. A case study of additive-subtractive methods for a patient-specific bone plate, demonstrates system capabilities and processing time reductions as compared to the current manual process planning for hybrid manufacturing methodologies. Using the generated FAH-PS process plan resulted in a 35% reduction in machining time from the current hybrid manufacturing strategy.

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Development of a modular computer-aided process planning (CAPP) system for additive-subtractive hybrid manufacturing of pockets, holes, and flat surfaces

Cited by 27 publications

References 17 publications

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

Hybrid subtractive–additive manufacturing processes for high value-added metal components

Advanced Manufacturing Using Linked Processes: Hybrid Manufacturing

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