Latest Developments in Industrial Hybrid Machine Tools That Combine Additive and Subtractive Operations

Cortina, Magdalena; Arrizubieta, Jon Iñaki; Ruiz, José Exequiel; Ukar, Eneko; Lamíkiz, Aitzol

doi:10.20944/preprints201811.0349.v1

Cited by 23 publications

(8 citation statements)

References 78 publications

(85 reference statements)

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“…Such a process is schematically presented in Figure 2; nonetheless, this technology is relatively new, and there are knowledge gaps due to limited in-practice use on process planning and monitoring, removal of powder, and so on. 8 The effect of various postprocessing techniques on fatigue strength of AM parts-including marine grade steels such as 316L-has been investigated in the past; however, to the best knowledge of the authors, thorough investigation of static and cyclic material properties resulting from different postprocessing routes, including a comparison with wrought material, has not been reported yet. Hence, this study investigates the fatigue strength of different postprocessing methods and the effect of cyclic mean stresses on PBF-LB/M and wrought 316L specimens.…”

Section: Introductionmentioning

confidence: 99%

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Fatigue strength of PBF‐LB/M and wrought 316L stainless steel: effect of post‐treatment and cyclic mean stress

Braun

Mayer²,

Kryukov

et al. 2021

Fatigue Fract Eng Mat Struct

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Additive manufacturing (AM) enables the cost-effective production of complex components, many of which are traditionally manufactured using costly subtractive processes. During laser-based powder bed fusion of metals (PBF-LB/M), internal pores and rough surfaces are typically inevitable, reducing fatigue and corrosion resistance compared to traditional processes.Additionally, large defects often occur near to or at surfaces. Thus, this study investigates the effect of hybrid additive and subtractive manufacturing on the fatigue strength of AISI 316L. To this goal, different post-treatment routes are compared with wrought material. Additionally, computed tomography is used to determine the necessary machining depth of the surface layer. In this study, heat treatment and machining are both found to significantly increase fatigue strength (17% and 87%). Finally, the mean stress sensitivity M of as-built PBF-LB/M and wrought material is found to be highly affected by the assessed number of cycles to failure and residual stresses in PBF-LB/M material.

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Section: Introductionmentioning

confidence: 99%

“…F I G U R E 2 Schematic illustration of a hybrid workflow combining additive and subtractive manufacturing processes; based on Cortina et al8 [Colour figure can be viewed at wileyonlinelibrary.com]…”

mentioning

confidence: 99%

Fatigue strength of PBF‐LB/M and wrought 316L stainless steel: effect of post‐treatment and cyclic mean stress

Braun

Mayer²,

Kryukov

et al. 2021

Fatigue Fract Eng Mat Struct

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“…Almost any weldable metal can be processed with any of these two techniques. Nevertheless, most hybrid systems integrate LMD, a DED technology that is faster than Selective Laser Melting (SLM), a PBF process, and does not need any process chamber or supporting structures [ 1 ]. However, the residual stress generated by these two processes is a challenge for thin-walled parts.…”

Section: Introductionmentioning

confidence: 99%

Deformation Prediction and Experimental Study of 316L Stainless Steel Thin-Walled Parts Processed by Additive-Subtractive Hybrid Manufacturing

Zhu

2021

Materials

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The hybrid process integrates two or more different processes, such as additive and subtractive manufacturing, which have gained appreciable consideration in recent years. The deformation of hybrid manufacturing is an essential factor affecting machining quality. The purpose of this paper is to study the effect of milling on stress release and surface deformation of additive manufacturing (AM) specimens in the process of additive and subtractive hybrid manufacturing (ASHM) of 316L stainless steel thin-walled parts, so as to effectively improve the forming quality of thin-walled parts manufactured by the combined processing of ASHM. To this end, a series of experiments were carried out to study the relationship between stress distribution and thermal stress deformation of 316L stainless steel thin-walled parts prepared by LMD, and the changes of stress and deformation of these thin-walled parts after subsequent milling. An infrared camera and laser distance sensor were used to record the temperature field data and deformation data to analyze the influence factors of temperature and stress on the machining results. Then, the finite element software was used to simulate the stress and deformation of the thin-walled parts in the additive manufacturing process and the subsequent milling process. Meanwhile, the model was verified through the experiments. In addition, the relationship between the milling force and the milling parameters of the AM parts was studied by orthogonal test and regression analysis.

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“…Overall, the main difference of DED processes compared to PBF is that DED generates the component by melting the powder at the same time it is being deposited on the substrate plate or on the previous layer [66][67][68]. The processes need to be either in a vacuum atmosphere or assisted by a shielding gas like argon [69]. Figure 8 shows a schematic of the DED process during the deposition of a pass with the aforementioned components.…”

Section: Direct Energy Deposition (Ded)mentioning

confidence: 99%

Metal additive manufacturing in the commercial aviation industry: A review

Gisario

Kazarian

Martina

et al. 2019

Journal of Manufacturing Systems

427

124

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The applications of Additive Manufacturing (AM) have been grown up rapidly in various industries in the past few decades. Among them, aerospace has been attracted more attention due to heavy investment of the principal aviation companies for developing the AM industrial applications. However, many studies have been going on to make it more versatile and safer technology and require making development in novel materials, technologies, process design, and cost efficiency. As a matter of fact, AM has a great potential to make a revolution in the global parts manufacturing and distribution while offering less complexity, lower cost, and energy consumption, and very highly customization. The current paper aims to review the last updates on AM technologies, material issues, postprocesses, and design aspects, particularly in the aviation industry. Moreover, the AM process is investigated economically including various cost models, spare part digitalization and environmental consequences. This review would be helpfully applied in both academia and industry as well.

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Latest Developments in Industrial Hybrid Machine Tools That Combine Additive and Subtractive Operations

Cited by 23 publications

References 78 publications

Fatigue strength of PBF‐LB/M and wrought 316L stainless steel: effect of post‐treatment and cyclic mean stress

Fatigue strength of PBF‐LB/M and wrought 316L stainless steel: effect of post‐treatment and cyclic mean stress

Deformation Prediction and Experimental Study of 316L Stainless Steel Thin-Walled Parts Processed by Additive-Subtractive Hybrid Manufacturing

Metal additive manufacturing in the commercial aviation industry: A review

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