Novel dynamic CAPP system for hybrid additive–subtractive–inspection process

Abstract

Purpose Hybrid manufacturing technologies combining individual processes can be recognized as one of the most cogent developments in recent times. As a result of integrating additive, subtractive and inspection processes within a single system, the relative benefits of each process can be exploited. This collaboration uses the strength of the individual processes, while decreasing the shortcomings and broadening the application areas. Notwithstanding its numerous advantages, the implementation of hybrid technology is typically affected by the limited process planning methods. The process planning methods proficient at effectively using manufacturing sources for hybridization are notably restrictive. Hence, this paper aims to propose a computer-aided process planning system for hybrid additive, subtractive and inspection processes. A dynamic process plan has been developed, wherein an online process control with intelligent and autonomous characteristics, as well as the feedback from the inspection, is utilized. Design/methodology/approach In this research, a computer-aided process planning system for hybrid additive, subtractive and inspection process has been proposed. A framework based on the integration of three phases has been designed and implemented. The first phase has been developed for the generation of alternative plans or different scenarios depending on machining parameters, the amount of material to be added and removed in additive and subtractive manufacturing, etc. The primary objective in this phase has been to conduct set-up planning, process selection, process sequencing, selection of machine parameters, etc. The second phase is aimed at the identification of the optimum scenario or plan. Findings To accomplish this goal, economic models for additive and subtractive manufacturing were used. The objective of the third phase was to generate a dynamic process plan depending on the inspection feedback. For this purpose, a multi-agent system has been used. The multi-agent system has been used to achieve intelligence and autonomy of different phases. Practical implications A case study has been developed to test and validate the proposed algorithm and establish the performance of the proposed system. Originality/value The major contribution of this work is the novel dynamic computer-aided process planning system for the hybrid process. This hybrid process is not limited by the shortcomings of the constituent processes in terms of tool accessibility and support volume. It has been established that the hybrid process together with an appropriate computer-aided process plan provides an effective solution to accurately fabricate a variety of complex parts.

Future of precision manufacturing: Integrating advanced metrology and intelligent monitoring for process optimization

“…This is complemented by research on the sequence planning of manufacturing features based on the node importance of complex networks, which contributes to the realization of adaptive manufacturing feature sequencing (Cheng et al, 2021). Furthermore, the design of a selflearning multi-agent framework for the adaptation of modular production systems and the development of a dynamic computer-aided process planning system highlight the significance of adaptive manufacturing processes in the context of intelligent monitoring (Scrimieri et al, 2021;Abdulhameed et al, 2018).…”

Evolution of Computer‐Aided Process Planning for Hybrid Additive/Subtractive Process

“…Abdulhameed et al [25] e concept of the multiagent system was proposed to develop a computer-aided process plan for the hybrid additive-subtractive-inspection process. It was based on a three-step methodology, namely, a static process plan, selection of optimum scenario, and dynamic process plan.…”

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

“…Therefore, HM technologies leverage AM’s strengths for complex geometries and SM’s precision for finished parts [ 34 ]. However, a dynamic process plan is required for HM where online process control with intelligent characteristics as well as the feedback from the inspection is deployed [ 35 ]. Thus, emphasis is given to flourish the techniques for deposition, material removal and hybridizing processes through smart toolpaths, where measurement techniques play an important role in the quality control [ 36 ].…”