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Title: Surface Qualification Toolpath Optimization for Hybrid Manufacturing

Journal Article · · Journal of Manufacturing and Materials Processing
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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.

Research Organization:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Sponsoring Organization:
USDOE
Grant/Contract Number:
AC05-00OR22725; EE0008303
OSTI ID:
1818180
Journal Information:
Journal of Manufacturing and Materials Processing, Journal Name: Journal of Manufacturing and Materials Processing Journal Issue: 3 Vol. 5; ISSN JMMPBJ; ISSN 2504-4494
Publisher:
MDPI AGCopyright Statement
Country of Publication:
Switzerland
Language:
English

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Related Subjects

36 MATERIALS SCIENCE
hybrid manufacturing
metal additive manufacturing
surface qualification
toolpath optimization