Process planning for hybrid additive and subtractive manufacturing to integrate machining and directed energy deposition

Chen, Niechen; Frank, Matthew C.

doi:10.1016/j.promfg.2019.06.140

Cited by 48 publications

(17 citation statements)

References 23 publications

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“…It has been reported that in non-HIP samples, exposed pores can hold contaminants that can leave defects during plating and harbour bacteria in medical applications. Therefore, HIP treatments are successful at enhancing the cleanliness and better polishing results can be achieved on processed surfaces, and thus to improve the surface integrity of components [27,28]. Furthermore, steels especially SS are widely used in the aerospace sector to produce engine and/or exhaust components, due to their superior high temperature tolerances and their good corrosion resistance.…”

Section: Application Areas Of Hybrid 316 L Stainless Steelmentioning

confidence: 99%

“…Furthermore, repeatability and microstructural consistency of produced hybrid components were not investigated and their surface integrity and mechanical performance were not optimised. Other researchers have attempted HCM, but success has been limited to manufacturing one-off component manufacture or to process planning without full investigations into components mechanical properties or optimisation [25][26][27][28].…”

Section: Introductionmentioning

confidence: 99%

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The Effect of Hot Isostatic Pressing on Surface Integrity, Microstructure and Strength of Hybrid Metal Injection Moulding, and Laser-Based Powder Bed Fusion Stainless-Steel Components

et al. 2021

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Hybrid manufacture of components by combining capabilities of replication and additive manufacturing processes offer a flexible and sustainable route for producing cost-effectively small batches of metal parts. At present, there are open issues related to surface integrity and performance of such parts, especially when utilising them in safety critical applications. The research presented in this paper investigates the ductility amplification of hybrid components produced using metal injection moulding to preform and then build on them customisable sections by laser-based powder bed fusion. The properties of such hybrid components are studied and optimised through the use of non-conventional post treatment techniques. In particular, hot isostatic pressing (HIP) is employed to improve mechanical strength and to produce hybrid components that have consistent properties across batches and throughout the samples, minimising microstructural heterogeneities between fabrication processes. Thus, the investigated post-processing method can offer an extended service life of hybrid components, especially when operating under severe conditions. The optimised post treatment was found to increase the hybrid components’ strength compared to as-built ones by 68% and ~11% in yield strength (YS) and ultimate tensile strength (UTS), respectively. Subsequently, leading to a great pitting resistance, thus, making HIP samples suitable for corrosive environments. The advantages of the HIP treatments in comparison to the conventional heat treatment of hybrid components are discussed and also some potential application areas are proposed.

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Section: Application Areas Of Hybrid 316 L Stainless Steelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

The Effect of Hot Isostatic Pressing on Surface Integrity, Microstructure and Strength of Hybrid Metal Injection Moulding, and Laser-Based Powder Bed Fusion Stainless-Steel Components

et al. 2021

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“…Compared to other interfaces previously proposed by Chen et al [15] and Boonsuk and Frank [15], the tool accessibility of LPBF parts was increased to ve sides by combining the three jaw-clamping system proposed by Relea et al [27] and Schlüssel et al [28] with integrated, support-free bolts. Furthermore, handling techniques, such as bolt removal, were signi cantly improved.…”

Section: Value Of the Designmentioning

confidence: 99%

Design and Validation of Integrated Clamping Interfaces for Post-Processing and Robotic Handling in Additive Manufacturing

Ferchow

Kälin

Englberger

et al. 2021

Preprint

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Additive manufacturing (AM), particularly laser-based powder bed fusion of metals (LPBF), enables the fabrication of complex and customized metallic parts. However, 20–40% of the total manufacturing costs are usually attributed to post-processing steps. To reduce the costs of extensive post-processing, the process chain for AM parts has to be automated. Accordingly, robotic gripping and handling processes, as well as an efficient clamping for subtractive machining of AM parts, are key challenges. This study introduces and validates integrated bolts acting as a handling and clamping interface of AM parts. The bolts are integrated into the part design and manufactured in the same LPBF process. The bolts can be easily removed after the machining process using a wrench. This feasibility study investigates different bolt elements. The experiments and simulations conducted in the study show that a force of 250 N resulted in a maximum displacement of 12.5 µm. The milling results of the LPBF parts reveal a maximum roughness value, Ra, of 1.42 µm, which is comparable to that of a standard clamping system. After the bolt removal, a maximum residual height of 0.067 mm remains. Two case studies are conducted to analyze the form deviation, the effect of bolts on build time and material volume and to demonstrate the application of the bolts. Thus, the major contribution of this study is the design and the validation of standardized interfaces for robotic handling and clamping of complex AM parts. The novelties are a simple and clean interface removal, less material consumption, less support structure required and finally an achievement of a five-side tool accessibility by combining the interfaces with a three-jaw chuck.

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“…Liou et al [4] were one of the first to investigate 5-axis hybrid manufacturing machine tools using powder feedstock DED, and their process generated the additive and subtractive toolpaths prior to the actual production process, such that the SM toolpath did not account for AM geometric defects. More recently, Chen et al [5] used the aforementioned toolpath generation approach, but this did not consider the actual as-built geometry in determination of SM toolpaths. Rodrigues et al [6] also investigated wire DED and applied traditional 3-axis SM facing operations to the top surfaces of as-built AM parts without using online measuring equipment to adjust the SM toolpath.…”

Section: Introductionmentioning

confidence: 99%

“…For manufacturing new components, Chen at al. [5] proposed a unique workflow where conventional stock material was partially machined and only certain features were deposited with AM and then subsequently machined. Zheng et al [25] developed a complex method involving feature extraction of the desired CAD geometry and the formulation of AM and SM toolpaths for remanufacturing components.…”

Section: Introductionmentioning

confidence: 99%

Surface Qualification Toolpath Optimization for Hybrid Manufacturing

Thien

Saldaña

2021

JMMP

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Hybrid manufacturing machine tools have great potential to revolutionize manufacturing by combining both additive manufacturing (AM) and subtractive manufacturing (SM) processes on the same machine tool. A prominent issue that can occur when going from AM to SM is that the SM process toolpath does not account for geometric discrepancies caused by the previous AM step, which leads to increased production times and tool wear, particularly when wire-based directed energy deposition (DED) is used as the AM process. This work discusses a methodology for approximating a part’s surface topology using on-machine contact probing and formulating an optimized SM toolpath using the surface topology approximation. Three different geometric surface approximations were used: triangular, trapezoidal, and a hybrid of both. SM toolpaths were created using each geometric approximation and assessed according to three objectives: reducing total machining time, reducing surface roughness, and reducing cutting force. Different prioritization scenarios of the optimization goals were also investigated. The optimal surface approximation that yielded the most improvement in the optimization was determined to be the hybrid surface topology approximation. Furthermore, it was shown that when the machining time or cutting force optimization goals were prioritized, there was little improvement in the other optimization goals.

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Process planning for hybrid additive and subtractive manufacturing to integrate machining and directed energy deposition

Cited by 48 publications

References 23 publications

The Effect of Hot Isostatic Pressing on Surface Integrity, Microstructure and Strength of Hybrid Metal Injection Moulding, and Laser-Based Powder Bed Fusion Stainless-Steel Components

The Effect of Hot Isostatic Pressing on Surface Integrity, Microstructure and Strength of Hybrid Metal Injection Moulding, and Laser-Based Powder Bed Fusion Stainless-Steel Components

Design and Validation of Integrated Clamping Interfaces for Post-Processing and Robotic Handling in Additive Manufacturing

Surface Qualification Toolpath Optimization for Hybrid Manufacturing

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