Hybrid metal additive/subtractive machine tools and applications

Smith, Scott; Schmitz, Tony; Feldhausen, Thomas; Sealy, Michael

doi:10.1016/j.cirp.2024.05.002

Hybrid metal additive/subtractive machine tools and applications

Journal Article · Fri Jul 26 00:00:00 EDT 2024 · CIRP Annals

DOI:https://doi.org/10.1016/j.cirp.2024.05.002· OSTI ID:2438963

^[1]; ^[2]; ^[1]; Sealy, Michael ^[3]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)
Purdue Univ., West Lafayette, IN (United States)

Additive manufacturing creates parts by depositing a preform, typically layer by layer. Subtractive manufacturing involves removing material from a preform to create parts. Hybrid machine tools combine both additive and subtractive processes in the same workspace. They can be used to create parts that meet functional tolerance and surface finish requirements, or to create features that are difficult to produce using additive or subtractive processes alone. Here, this paper describes hybrid metal additive/subtractive machine tools. It covers design considerations, sensors and controls, process management, programming and software, and the impact on the design space. It also identifies future research challenges.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOD; USDOE

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2438963

Alternate ID(s):: OSTI ID: 2449661

Journal Information:: CIRP Annals, Journal Name: CIRP Annals Journal Issue: 2 Vol. 73; ISSN 0007-8506

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Evolution of Computer‐Aided Process Planning for Hybrid Additive/Subtractive Process Abdulhameed, Osama; Al-Ahmari, Abdulrahman; Mian, Syed Hammad Advances in Materials Science and Engineering, Vol. 2020, Issue 1 https://doi.org/10.1155/2020/7458239	journal	January 2020
Hybrid layered manufacturing: Direct rapid metal tool-making process Karunakaran, K. P.; Sreenathbabu, A.; Pushpa, V. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 218, Issue 12 https://doi.org/10.1177/095440540421801202	journal	December 2004
Experimental investigation of laser hot-wire cladding Liu, Shuang; Liu, Wei; Kovacevic, Radovan Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 231, Issue 6 https://doi.org/10.1177/0954405415578722	journal	April 2015
Investigation of hybrid manufacturing of stainless steel 316L components using direct energy deposition Tapoglou, Nikolaos; Clulow, Joseph Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture https://doi.org/10.1177/0954405420949360	journal	August 2020
Additive manufacturing–assisted conformal cooling channels in mold manufacturing processes Shinde, Mahesh S.; Ashtankar, Kishor M. Advances in Mechanical Engineering, Vol. 9, Issue 5 https://doi.org/10.1177/1687814017699764	journal	May 2017
Hybrid manufacturing of metallic parts integrated additive and subtractive processes Grzesik, Wit Mechanik, Issue 7 https://doi.org/10.17814/mechanik.2018.7.58	journal	July 2018
A Preliminary Design of a Hybrid Machine for Additive and Subtractive Manufacturing Sutisna, Nanang Ali Journal of Mechanical Engineering and Mechatronics, Vol. 5, Issue 1 https://doi.org/10.33021/jmem.v5i1.919	journal	April 2020
Evaluation and Optimization of a Hybrid Manufacturing Process Combining Wire Arc Additive Manufacturing with Milling for the Fabrication of Stiffened Panels Li, Fang; Chen, Shujun; Shi, Junbiao Applied Sciences, Vol. 7, Issue 12 https://doi.org/10.3390/app7121233	journal	November 2017
Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls Vaughan, Derek; Saldana, Christopher; Kurfess, Thomas Journal of Manufacturing and Materials Processing, Vol. 6, Issue 4 https://doi.org/10.3390/jmmp6040070	journal	June 2022
Latest Developments in Industrial Hybrid Machine Tools that Combine Additive and Subtractive Operations Cortina, Magdalena; Arrizubieta, Jon; Ruiz, Jose Materials, Vol. 11, Issue 12 https://doi.org/10.3390/ma11122583	journal	December 2018
Analysis of Melt Pool Characteristics and Process Parameters Using a Coaxial Monitoring System during Directed Energy Deposition in Additive Manufacturing Kledwig, Christian; Perfahl, Holger; Reisacher, Martin Materials, Vol. 12, Issue 2 https://doi.org/10.3390/ma12020308	journal	January 2019
Analysis of the Machining Process of Inconel 718 Parts Manufactured by Laser Metal Deposition Ostra, Txomin; Alonso, Unai; Veiga, Fernando Materials, Vol. 12, Issue 13 https://doi.org/10.3390/ma12132159	journal	July 2019
Analysis of the Machining Process of Titanium Ti6Al-4V Parts Manufactured by Wire Arc Additive Manufacturing (WAAM) Veiga, Fernando; Gil Del Val, Alain; Suárez, Alfredo Materials, Vol. 13, Issue 3 https://doi.org/10.3390/ma13030766	journal	February 2020
Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling Sommer, David; Götzendorfer, Babette; Esen, Cemal Materials, Vol. 14, Issue 19 https://doi.org/10.3390/ma14195753	journal	October 2021
Tool Wear and Milling Characteristics for Hybrid Additive Manufacturing Combining Laser Powder Bed Fusion and In Situ High-Speed Milling Sommer, David; Pape, Dominik; Esen, Cemal Materials, Vol. 15, Issue 3 https://doi.org/10.3390/ma15031236	journal	February 2022
Effect of Heat Treatment on the Microstructure and Mechanical Properties of 18Ni-300 Maraging Steel Produced by Additive–Subtractive Hybrid Manufacturing Osman, Mahmoud; Sarafan, Sheida; Wanjara, Priti Materials, Vol. 16, Issue 13 https://doi.org/10.3390/ma16134749	journal	June 2023
Case Study to Illustrate the Potential of Conformal Cooling Channels for Hot Stamping Dies Manufactured Using Hybrid Process of Laser Metal Deposition (LMD) and Milling Cortina, Magdalena; Arrizubieta, Jon; Calleja, Amaia Metals, Vol. 8, Issue 2 https://doi.org/10.3390/met8020102	journal	February 2018
Economic and Ecological Evaluation of Hybrid Additive Manufacturing Technologies Based on the Combination of Laser Metal Deposition and CNC Machining Lutter-Günther, Max; Wagner, Stephan; Seidel, Christian Applied Mechanics and Materials, Vol. 805 https://doi.org/10.4028/www.scientific.net/AMM.805.213	journal	November 2015
Hybrid Additive and Subtractive Manufacturing Processes and Systems: a Review Grzesik, Wit Journal of Machine Engineering, Vol. 18, Issue 4 https://doi.org/10.5604/01.3001.0012.7629	journal	November 2018

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