Technical and Economic Implications of the Combination of Machining and Additive Manufacturing in the Production of Metal Parts on the Example of a Disc Type Element

Grzesiak, Dariusz; Terelak-Tymczyna, Agnieszka; Bachtiak-Radka, Emilia; Filipowicz, Krzysztof

doi:10.1007/978-3-030-49910-5_12

Cited by 3 publications

(5 citation statements)

References 5 publications

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“…This due to the very long production time of the unit production (37 hours and 36 minutes), which has a direct impact on the rate of increase in electricity demand along with the increase in the production batch. The conducted result confirm the results obtained by Grzesiak et al in [31].…”

Section: Obtained Resultssupporting

confidence: 92%

“…The obtained results allow to conclude that, taking into account the profitability criterion for unit production, the hybrid method is recommended. The conducted research confirmed the results obtained in the article by Grzesiak et al [31] where unit production was analyzed. At the same time, the simulation studies carried out showed that for the production of 10 items of products, hybrid production is unprofitable, both in terms of time, production costs and energy consumption.…”

Section: Recapitulationsupporting

confidence: 88%

“…In order to meet all the guidelines for the conducted experiment, in the article, according to Grzesiak et al [31] the main assumptions were made, which are presented in Table 2. production costs, taking into account the labor costs of the operator, technology and quality controller, as well as the costs of energy, materials and tools used.…”

Section: Initial Assumptions For the Researchmentioning

confidence: 99%

“…The comparative analysis of classical and hybrid processing was carried out by Grzesiak et.al. [31], who in the article presented a comparison of the production of one product with the classic method and the hybrid method. In the literature on the subject, no issues related to the modeling and simulation of both processes for different production batches have been found, which allows to determine the profitability of production and reduce uncertainty with the implementation of new production systems in changing market conditions.…”

Section: Introductionmentioning

confidence: 99%

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Comparative Analysis of the Production Process of a Flange-Type Product by the Hybrid and Traditional Method with the Use of Simulation Methods

Terelak-Tymczyna¹,

Bachtiak-Radka²,

Jardzioch³

2022

Adv. Sci. Technol. Res. J.

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In the era of Industry 4.0, the digitization of production processes is one of the important elements contributing to the reduction of uncertainty related to the implementation of new production methods. The worldwide epidemic situation and its constraints have resulted in supply chain continuity problems. These problems make enterprises look for the possibility of producing products that they need at the moment and which they cannot obtain from the market. In special cases, this may also apply to spare parts necessary to maintain the continuity of production. The main reason for research on comparing production processes is meeting the challenges related to the pandemic situation and problems in maintaining timeliness, fl exibility, and continuity of the supply chain. The fi rst stage of the research was to visualize the course of the process and determine the lead times for both production methods. For further analysis, a digital process model was used to compare the hybrid and the classical method to check the viability of the interchangeability of methods for the production process of the fl ange part. The interchangeability of production methods was dictated by problems related to the supply of components for the execution of orders. The article simulates the model for unit and small-lot production in batches of 10 and 100 pieces, considering such aspects as: order completion time, energy consumption of the process, production costs, taking into account the classic and hybrid methods. The conducted research was aimed at determining the profi tability of the production of fl ange-type products by means of classical processing and hybrid and checking the interchangeability of production methods in accordance with quality requirements as well as reducing uncertainty with the implementation of new production systems in changing market conditions. The simulations show that the use of hybrid production is recommended for unit production. In the case of small-lot production, already with 10 items, production in the traditional process is 21% cheaper, and for the production of 100 items, the cost of traditional production is reduced by 33% compared to hybrid production.

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Section: Obtained Resultssupporting

confidence: 92%

Section: Recapitulationsupporting

confidence: 88%

Section: Initial Assumptions For the Researchmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Comparative Analysis of the Production Process of a Flange-Type Product by the Hybrid and Traditional Method with the Use of Simulation Methods

Terelak-Tymczyna¹,

Bachtiak-Radka²,

Jardzioch³

2022

Adv. Sci. Technol. Res. J.

Self Cite

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“…To do this, businesses need to make important decisions. A tool helpful in making decisions related to production planning can be a simulation model [2,3,4] which, based on real data from the process, allows for the verification of decisions before entering them into the real system [5,6].In the literature, you can find examples of modelling e-business processes [7,8] and the extension of models to supply chains [9], as well as descriptions of the benefits of using a new methodological approach to develop static and dynamic simulation models [10,11]. In [12] the simulation was used to test the real system model and see the results of the optimization of the production system in concrete conditions, which bring specific improvements in concrete case -increased pieces of final product, better utilization of production time and reduction of storage times to minimum.…”

Section: Introductionmentioning

confidence: 99%

Comparison of the Classic and Hybrid Production Methods with the Use of SLM Taking into Account the Aspects of Sustainable Production Development

Terelak-Tymczyna¹,

Bachtiak-Radka²,

Grzesiak³

et al. 2023

Adv. Sci. Technol. Res. J.

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Problems on the world market, related to delays in supply chains, have forced enterprises to adopt a more fl exible approach in the production processes of the off ered products. In order to meet customer needs, companies can often look for alternative supply chains, as well as take over the production of key components necessary to maintain business continuity. Therefore, companies have to make important decisions in the context of management. A simulation model may be a tool helpful in making decisions related to production planning, which, based on the actual data collected from the process, allows for the verifi cation of decisions before entering them into the real system. The motivation to conduct the research was the search for answers: How entrepreneurs, while maintaining profi tability, can ensure the continuity of production processes by searching for alternative production methods. The article considers a comparison of two production processes for the production of a shield type product: classic production -on a lathe and hybrid production using the SLM method and machining only technologically signifi cant surfaces on a lathe. The main goal of the research is to compare two production processes: classic and hybrid in terms of effi ciency, energy effi ciency and production costs. The research takes into account the use of diff erent laser powers and the possibility of incremental production of several products at the same time. In order to achieve the assumed goal, a simulation model was used to carry out the research, which was developed on the basis of preliminary experimental studies. A series of simulations were performed, taking into account the variability criteria, and then the effi ciency, energy effi ciency and profi tability of using alternative production methods were analysed. The purpose of the article is comparison of two production processes, classic and hybrid, in terms of effi ciency, production costs and electricity consumption.

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Revolutionising orthopaedic implants—a comprehensive review on metal 3D printing with materials, design strategies, manufacturing technologies, and post-process machining advancements

Shaikh,

Kahwash,

et al. 2024

Int J Adv Manuf Technol

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This paper conceptualises an understanding of advanced manufacturing methods to develop 3D-printed metallic orthopaedic implants, including a brief discussion on post-process machining. The significance of Metallic Additive Manufacturing (MAM) and its practicality for industrial applications is discussed through a juxtaposition with conventional casting and machining approach. Different alloys and suitable MAM techniques are thoroughly reviewed to determine optimum operating conditions. Although MAM can produce near-net shape parts, post-processing is an unavoidable requirement to improve surface quality and dimensional accuracy. A comparative study is presented, highlighting the importance of machining for post-processing in terms of cost savings and performance. Different materials are evaluated aiming to overcome problems associated with existing orthopaedic implants. The consequence of bone-implant mechanical mismatch leading to stress shielding and inadequate corrosion properties obstructing biodegradability are explored in detail. The effect of additive manufacturing parameters on mechanical, corrosion, and surface properties including biocompatibility is analysed. Evidence of MAM’s advantages over conventional manufacturing approaches, such as the use of functionally graded lattices and patient-specific customised designs, is also presented. Finally, for future studies, a two-way approach is conceptualised with material selection and manufacturing process control in progressions of implant development using MAM. Graphical Abstract

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Technical and Economic Implications of the Combination of Machining and Additive Manufacturing in the Production of Metal Parts on the Example of a Disc Type Element

Cited by 3 publications

References 5 publications

Comparative Analysis of the Production Process of a Flange-Type Product by the Hybrid and Traditional Method with the Use of Simulation Methods

Comparative Analysis of the Production Process of a Flange-Type Product by the Hybrid and Traditional Method with the Use of Simulation Methods

Comparison of the Classic and Hybrid Production Methods with the Use of SLM Taking into Account the Aspects of Sustainable Production Development

Revolutionising orthopaedic implants—a comprehensive review on metal 3D printing with materials, design strategies, manufacturing technologies, and post-process machining advancements

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