The development of a novel process planning algorithm for an unconstrained hybrid manufacturing process

Zhu, Zhenshu; Dhokia, Vimal; Newman, Stephen T.

doi:10.1016/j.jmapro.2013.06.006

Cited by 51 publications

(23 citation statements)

References 26 publications

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“…This is based on the need to reuse and remanufacture existing parts or even recycled and legacy parts; enhance the flexibility of CNC machining and improve the accuracy of FFF process [30]. Incorporating an additive process releases design constraints often caused by tool accessibility issues in CNC machining.…”

Section: The Hybrid Process -Iatractivementioning

confidence: 99%

“…Given that the process plan for manufacturing a part using the iAtractive process is generated based on the part design, features and the dimensions are the most accessible geometrical information for the iAtractive process [28][29][30]. The mathematical model is thus focused on part dimensions that affect the degree of distortions, and the material properties that essentially cause distortions.…”

Section: A Simplified Mathematical Modelmentioning

confidence: 99%

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Investigation of part distortions as a result of hybrid manufacturing

Zhu

Dhokia

Nassehi

et al. 2016

Robotics and Computer-Integrated Manufacturing

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a b s t r a c tIn today's society, the customer driven markets has led to the rapid developments and continuous evolution of manufacturing technologies. The ability to accurately produce complex parts, and to reuse and remanufacture used parts is becoming more prevalent, requiring more efficient and rapid methods to be developed. One such method being currently developed is the hybrid process combining additive, subtractive and inspection processes for the manufacture of complex part geometries from any given raw material in terms of shape and size. A major element of the hybrid process is decomposition of a part into a number of subparts, which are additively manufactured and machined in sequence. However, the residual stresses resulting from the temperature difference between the solidified material (i.e. already manufactured subparts) and the material being deposited (i.e. new subparts being built) leads to part distortions, which significantly reduces the dimensional accuracy of finished parts. This study investigates part distortions that take place in the additive manufacturing process under the context of hybrid manufacturing. A method for conducting this investigation was first proposed. A mathematical model was developed, identifying the influential parameters that contribute to part distortions. These parameters were then incorporated in the experimental design by employing the Taguchi design of experiments strategy. Distortion behaviour arising from thermally induced stress was experimentally explored, indicating that part length, height, and layer thickness have significant effects on part distortions.

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Section: The Hybrid Process -Iatractivementioning

confidence: 99%

Section: A Simplified Mathematical Modelmentioning

confidence: 99%

Investigation of part distortions as a result of hybrid manufacturing

Zhu

Dhokia

Nassehi

et al. 2016

Robotics and Computer-Integrated Manufacturing

Self Cite

View full text Add to dashboard Cite

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“…Ren et al [17] developed an integrated process planning framework for hybrid manufacturing with additive and subtractive processes (direct metal deposition and CNC machining). Similarly, Zhu et al [18] presented a process planning method for a hybrid additive and subtractive system (fused deposition modelling and CNC machining). Both studies focussed on splitting a geometric part into smaller volumes, for which the optimal manufacturing sequence was identified.…”

Section: Integration Of Product Design and Manufacturing Capability Datamentioning

confidence: 99%

“…Although the designer is supported in the analysis of a 3D CAD product design, the presented method cannot be used to support the translation of a concept design into that initial 3D CAD model. This limitation also exists for the methodologies A decision-support methodology for embodiment design and process chain selection for hybrid manufacturing platforms 5 of Ren et al [17] and Zhu et al [18], which similarly require the input of a 3D CAD model to enable analysis of a detailed design as opposed to supporting the early design stages.…”

Section: Integration Of Product Design and Manufacturing Capability Datamentioning

confidence: 99%

A decision support methodology for embodiment design and process chain selection for hybrid manufacturing platforms

Gleadall

Vladov

Segal

et al. 2016

Int J Adv Manuf Technol

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This paper presents a methodology for the transformation of a product concept into a detailed design and manufacturing process chain for hybrid manufacturing platforms. Hybrid platforms offer new capabilities and opportunities for product design. However, they require high levels of process expertise for effective design and effective process selection. Design for hybrid manufacture is challenging as there is a requirement to understand a number of technologies, which may be highly varied. To address this challenge, a knowledgebased decision-support system developed in this paper enables manufacturing expertise to be integrated into procedures for product design and process chain selection. This formalised numerical methodology is able to consider a wider range of varied manufacturing processes than any previous study. A feature-based design method is developed, which guides the designer towards an optimised product design during the embodiment design phase, and a process-chain selection program is utilised to enable the effective analysis of a product design based on product evaluation criteria. The methodology has been successfully applied to the design of an LED product with internal geometries and electronics.A decision-support methodology for embodiment design and process chain selection for hybrid manufacturing platforms 2 Key words:Design for manufacture, process chain selection, hybrid manufacture, feature-based design, decisionsupport. Acknowledgements:The research leading to these results has received funding from the European Union Seventh Framework Programme (FP7/2007(FP7/ -2013 under grant agreement number 314580.

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“…fused filament fabrication, known as FFF), 1 subtractive (i.e. CNC machining) and inspection processes (Zhu et al 2013b). This is based on the need to reuse and remanufacture existing parts or even recycled and legacy parts.…”

Section: A Novel Concept Of Hybrid Manufacturing Processmentioning

confidence: 99%

A novel decision-making logic for hybrid manufacture of prismatic components based on existing parts

2014

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The on-going industrial trend towards high value sustainable manufacturing has led to the emergence of hybrid manufacturing processes. This new generation of processes combines the capabilities of a number of individual manufacturing processes on a single platform. Despite the fact that the drawbacks of individual processes have been significantly reduced, the application of hybrid technology has always been constrained by the capabilities of their constituent processes, in particular the capability to utilise various raw materials in terms of shape and size. This paper introduces a novel concept of hybrid process, which consists of combining additive, subtractive and inspection processes. A feature-based decision-making logic is developed, enabling the hybrid process to reuse existing parts/legacy products. An existing part is first measured for obtaining its geometrical information. Feasible manufacturing strategies are provided and then additive, subtractive and inspection processes are utilised interchangeably to add and/or remove material, transforming the existing part into the final part. This indicates that the iAtractive process is not restricted by raw material geometries. Three identical test parts were manufactured from three existing different shaped parts, demonstrating the efficacy of the proposed hybrid process and the decisionmaking logic in material reuse. New features can be added onto the existing parts and existing features can be removed or further manufactured, giving these parts additional lives, new uses and increased functionality.

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The development of a novel process planning algorithm for an unconstrained hybrid manufacturing process

Cited by 51 publications

References 26 publications

Investigation of part distortions as a result of hybrid manufacturing

Investigation of part distortions as a result of hybrid manufacturing

A decision support methodology for embodiment design and process chain selection for hybrid manufacturing platforms

A novel decision-making logic for hybrid manufacture of prismatic components based on existing parts

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