Geometry-Based Decomposition Rules and Programming Strategies for Complex Components in Additive and Hybrid Manufacturing

Abstract

Additive manufacturing (AM) processes offer a promising avenue for providing service components, primarily due to their inherent advantage of producing components without the need for tooling or fixtures. Nevertheless, many AM processes often necessitate extensive post-processing steps to eliminate support materials and achieve the required surface finishes and feature tolerances. The central objective of this research is to investigate the feasibility of using directed energy deposition (DED) AM solutions to manufacture intricated geometries that are traditionally produced through casting, machining, or forging, leveraging hybrid manufacturing build techniques where machining operations are introduced as needed. DED AM processes with innovative tool paths and build strategies are employed to create a near-net shape, followed by final machining or intermittent machining operations. To structure our approach, we introduce a geometry classification schema, which allows us to group similar build strategies. This classification framework lays the foundation for our decomposition methods and process planning strategies. Some issues, such as overhang geometries and collisions, have been resolved using these specific strategies. It is important to note that this research is ongoing, and in future work, we plan to develop in-line heat maps and explore heating cycles impact on the resulting mechanical, tribological and physical properties of these components. This continued exploration will further enhance our understanding of the potential of DED AM in this context.