Meeting high precision requirements of additively manufactured components through hybrid manufacturing

Loyda, Alejandro; Arizmendi, M.; Galarreta, Sergio Ruiz de; Rodríguez-Flórez, Naiara; Jiménez, Amaia

doi:10.1016/j.cirpj.2022.11.011

Cited by 9 publications

(2 citation statements)

References 34 publications

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“…However, these hybridizations require an extensive analysis for optimizing the numerous variables associated with both technologies, which vary significantly from one another, in addition to those introduced by the material to be manufactured. Previous studies have examined optimal over-dimensioning and parameterization for laser-based powder bed fusion (PBF-LB) and 5-axis milling of Ti6Al4V material, resulting in significant improvements in surface quality after hybridization, except in holes or channels where direct machining remains the preferable option [ 30 ]. The variables, such as laser power, welding speed, or bead distance, have also been analyzed in the hybridization of machining and wire welding technology using CO 2 laser radiation [ 31 ], or injection molds have been successfully produced through selective laser cladding (SLC) and subsequent milling [ 32 ].…”

Section: Introductionmentioning

confidence: 99%

“…Some authors have developed custom artifacts with multiple geometries to analyze the dimensional accuracy and corresponding standard tolerances according to ISO 286-1:1988 [34]. In other cases, dimensional analysis has been applied to specific parts with real applications [23,30] or to artifacts proposed by national organizations [35,36]. Dimensional tolerances in 17-4PH stainless steel artifacts without standardization have also been characterized using ADAM technology, obtaining IT12 and IT13 tolerances [22], as well as surface roughness values close to laser-sintered components [37].…”

Section: Introductionmentioning

confidence: 99%

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Dimensional Characterization and Hybrid Manufacturing of Copper Parts Obtained by Atomic Diffusion Additive Manufacturing, and CNC Machining

Monzón,

Bordón,

Paz

et al. 2024

Materials

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The combination of Atomic Diffusion Additive Manufacturing (ADAM) and traditional CNC machining allows manufacturers to leverage the advantages of both technologies in the production of functional metal parts. This study presents the methodological development of hybrid manufacturing for solid copper parts, initially produced using ADAM technology and subsequently machined using a 5-axis CNC system. The ADAM technology was dimensionally characterized by adapting and manufacturing the seven types of test artifacts standardized by ISO/ASTM 52902:2019. The results showed that slender geometries suffered warpage and detachment during sintering despite complying with the design guidelines. ADAM technology undersizes cylinders and oversizes circular holes and linear lengths. In terms of roughness, the lowest results were obtained for horizontal flat surfaces, while 15° inclined surfaces exhibited the highest roughness due to the stair-stepping effect. The dimensional deviation results for each type of geometry were used to determine the specific and global oversize factors necessary to compensate for major dimensional defects. This also involved generating appropriate over-thicknesses for subsequent CNC machining. The experimental validation of this process, conducted on a validation part, demonstrated final deviations lower than 0.5% with respect to the desired final part, affirming the feasibility of achieving copper parts with a high degree of dimensional accuracy through the hybridization of ADAM and CNC machining technologies.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Dimensional Characterization and Hybrid Manufacturing of Copper Parts Obtained by Atomic Diffusion Additive Manufacturing, and CNC Machining

Monzón,

Bordón,

Paz

et al. 2024

Materials

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A case study of hybrid manufacturing of a Ti-6Al-4V titanium alloy hip prosthesis

Festas,

Figueiredo,

Carvalho

et al. 2023

Int J Adv Manuf Technol

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Hybrid manufacturing (HM) is a process that combines additive manufacturing (AM) and subtractive manufacturing (SM). It is becoming increasingly recognized as a solution capable of producing components of high geometric complexity, while at the same time ensuring the quality of the surface finish, rigour and geometric tolerance on functional surfaces. This work aims to study the surface finish quality of an orthopaedic hip resurfacing prosthesis obtained by HM. For this purpose, test samples of titanium alloy Ti-6Al-4V using two Power Bed Fusion (PBF) processes were manufactured, which were finished by turning and 5-axis milling. It was verified that, upon the machining tests, no differences in Ra and Rt were found between the various types of AM. Regarding the type of SM used, 5-axis milling provided lower roughness results with a consistent value of Ra = 0.6 µm. The use of segmented circle mills in 5-axis milling proved to be an asset in achieving a good surface finish. This work successfully validated the concept of HM to produce a medical device, namely, an orthopaedic hip prosthesis.As far as surface quality is concerned, it could be concluded that the optimal solution for this case study is 5-axis milling.

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Hybrid metal additive/subtractive machine tools and applications

Smith,

Schmitz,

Feldhausen

et al. 2024

CIRP Annals

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Meeting high precision requirements of additively manufactured components through hybrid manufacturing

Cited by 9 publications

References 34 publications

Dimensional Characterization and Hybrid Manufacturing of Copper Parts Obtained by Atomic Diffusion Additive Manufacturing, and CNC Machining

Dimensional Characterization and Hybrid Manufacturing of Copper Parts Obtained by Atomic Diffusion Additive Manufacturing, and CNC Machining

A case study of hybrid manufacturing of a Ti-6Al-4V titanium alloy hip prosthesis

Hybrid metal additive/subtractive machine tools and applications

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