Integrated Process Planning for a Multiaxis Hybrid Manufacturing System

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Lan Ren ◽  
Todd Sparks ◽  
Jianzhong Ruan ◽  
Frank Liou
Keyword(s):  
Process Planning ◽  
Manufacturing Process ◽  
Computer Aided Design ◽  
Manufacturing System ◽  
Deposition Process ◽  
Cnc Machining ◽  
Machining Process ◽  
Hybrid Manufacturing ◽  
Integrated Process ◽  
Planning Framework

A hybrid manufacturing system integrates computer numerical controlled (CNC) machining process and layered deposition process and achieves the benefits of both processes. An integrated process planning framework, which includes every module of the hybrid manufacturing process is critical for making the building of functional parts feasible and reliable. In this paper, the hybrid manufacturing system is introduced and the integrated process planning framework, which aims to automate the hybrid manufacturing is investigated. Critical components of the process planning, including decomposition of the computer-aided design (CAD) model, improvement of the toolpath generation pattern, and collision detection algorithms, are discussed. The interfacing and integrating process between deposition and surface finish machining is also studied. The goal of integrated process planning is to realize the automatic hybrid manufacturing process without much human interference. Experiments are implemented to validate the feasibility and reliability of the integrated process planning framework.

Automatic Toolpath Generation for Multi-Axis Surface Machining in a Hybrid Manufacturing System

2003 ◽  
Author(s):  
Jianzhong Ruan ◽  
F. W. Liou
Keyword(s):  
Manufacturing System ◽  
Cutting Tools ◽  
Deposition Process ◽  
Machining Process ◽  
Hybrid Manufacturing ◽  
Cnc Machine ◽  
Surface Machining ◽  
Visibility Map ◽  
Cutter Path ◽  
Cutter Path Generation

In a multi-axis hybrid manufacturing system, it is necessary to utilize a machining process to improve surface accuracy and guarantee overall geometry after the deposition process. Due to the complexity of the multi-axis system, it is necessary to find proper orientations of cutting tools for the CNC machine to finish surface machining. This paper presents an algorithm to find collision-free surface machining toolpath for a given workpiece. The concept of the 2-D visibility map and its properties are discussed. The algorithm to compute the 2-D visibility map is presented. With the help of the 2-D visibility map, an optimal a collision free tool approaching direction can be easily decided. Also the type of the surface machining toolpath for different types of surfaces is decided based on topological information and the machining toolpath (CL data for milling tool). The developed planning scheme has been tested via machine simulations and has shown that it can be effectively applied to cutter-path generation for multi-axis surface machining.

Automated post machining process planning for a new hybrid manufacturing method of additive manufacturing and rapid machining

2018 ◽  
Vol 24 (7) ◽  
pp. 1077-1090 ◽  
Author(s):  
Niechen Chen ◽  
Prashant Barnawal ◽  
Matthew Charles Frank
Keyword(s):  
Additive Manufacturing ◽  
Process Planning ◽  
Manufacturing Process ◽  
Machining Process ◽  
Hybrid Manufacturing ◽  
High Quality ◽  
Content Type ◽  
Machining Process Planning ◽  
Quality Surface ◽  
High Quality Surface

PurposeThe purpose of this paper is to present a new method for automated post machining process planning for a hybrid manufacturing process. The manufacturing process is expected to generate complex functional parts by taking advantage of free form surface creation from additive manufacturing and high-quality surface finishing from CNC milling. Design/methodology/approachThe hybrid process starts with additive manufacturing to generate a near net shape part with pre-defined machining allowances on surfaces requiring high quality surface or tight tolerances, along with integrated fixture geometry. The next step is to conduct automated machining process planning to determine critical parameters such as setup angle, tool selection, depth, tool containment, and consequently, the NC code to machine the part. FindingsThis method is shown to be a feasible solution for rapidly creating functional parts. The tests have been conducted to validate the method developed in this paper. Originality/valueThis paper introduces a new automated post machining process planning method for integrating additive manufacturing with a rapid milling process.

Rule-Based Process Selection of Hole Making Operations for Integrated Process Planning

2005 ◽  
Author(s):  
Dusan N. Sormaz ◽  
Pravin Khurana ◽  
Ajit Wadatkar
Keyword(s):  
User Interface ◽  
Manufacturing System ◽  
Selection Procedure ◽  
Machining Process ◽  
Integrated Process ◽  
Process Selection ◽  
Rule Based ◽  
Hole Making ◽  
Significant Attention ◽  
Selection Of

Process selection as a part of CAPP has captured significant attention in CAPP research. Procedures have been developed for backward and forward algorithms in process selection. Most of these procedures lack the complete integration of process selection into CAPP system. In this paper, we present the results of the development and prototype implementation for process selection module for hole making operations for integration with Math Based Manufacturing System already in use in industrial partner. We have developed architecture and implemented module for rule-based machining process selection of hole making operations. The architecture enables the interface from the Process Selection prototype to Math Based Manufacturing System (APPS). The prototype also includes the user interface for interaction with the process selection procedure. Actions for starting prototype from APPS, performing process selection steps and sending the result back to APPS have been developed and implemented.

The Remanufacture of a Complex Part Using Hybrid Manufacturing (HM))

2021 ◽  
Author(s):  
German Alberto Barragan ◽  
Rodrigo Jose Ferreira ◽  
Fabio Mariani ◽  
Eraldo Jannone da Silva ◽  
Reginaldo Coelho
Keyword(s):  
Mechanical Performance ◽  
Complex Geometry ◽  
Deposition Process ◽  
Carbon Steels ◽  
Cnc Machining ◽  
Environmental Benefits ◽  
Hybrid Manufacturing ◽  
Wide Range ◽  
Aisi 1045 ◽  
Directed Energy

Abstract The industrial importance of repair and remanufacturing processes has significantly increased over the past years, primarily due to their possible cost reductions and environmental benefits. Different techniques have been used for the development of such tasks in different areas, however, restrictions have been encountered in parts of high geometric complexity or those that require high mechanical performance. Additive Manufacturing (AM) technologies are an interesting alternative for remanufacturing, due to their advantageous mechanical properties and possible application in operations involving complex geometries. Hybrid Manufacturing (HM) technologies, which combine the advantages of AM processes with CNC machining in the same machine, have arisen as a new method that modernizes the repair and remanufacturing of metal components and offers a range of possible combinations of materials. This article addresses a remanufacturing operation that involves the use of an HM applied to an AISI 1045 component repaired with the addition of AISI 316L steel. The properties of the final parts showed the viability of the process for the remanufacturing of components of different materials and complex geometry. The parameters and strategy employed for the deposition of the additive material allowed us to obtain a piece without significant porosity, cracks, or defects. Microstructure and hardness in the sample were like those obtained in other published works. The manufacture or remanufacturing of components by the Directed Energy Deposition process employing stainless steel deposition on top of carbon steels opens a wide range of new applications. Those include the deposition and machining of complex 3D geometries

An Integrated Process Planning System Architecture for Machining and On-Machine Inspection

2008 ◽  
Author(s):  
Yaoyao F. Zhao ◽  
Xun W. Xu ◽  
Sheng Q. Xie ◽  
Tom R. Kramer ◽  
Fred M. Proctor ◽  
...  
Keyword(s):  
Real Time ◽  
Process Planning ◽  
System Architecture ◽  
Data Model ◽  
Machining Process ◽  
Planning System ◽  
Integrated Process ◽  
Process Planning System ◽  
Inspection Process ◽  
Manufacturing Chain

Inspection is an essential part of the entire manufacturing chain providing measurement feedback to the process planning system. Fully automated machining requires automatic inspection process planning and real-time inspection results feedback. As inspection process planning is still based on G&M codes containing low-level information or vendor-specific bespoke routines, inspection process planning is mostly isolated from machining process planning. With the development of new data model standards STEP and STEP-NC providing high-level product information for the entire manufacturing chain, it is achievable to combine machining and inspection process planning to generate optimal machining and inspection sequences with real-time measurement results feedback. This paper introduces an integrated process planning system architecture for combined machining and inspection. In order to provide real-time inspection feedback, On-Machine Inspection (OMI) is chosen to carry out inspection operations. Implementation of the proposed architecture has been partially carried out with a newly developed data model and interpreter software. A case study was carried out to test the feasibility of the proposed architecture.

scholarly journals Direct Digital Subtractive Manufacturing of a Functional Assembly Using Voxel-Based Models

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Roby Lynn ◽  
Mahmoud Dinar ◽  
Nuodi Huang ◽  
James Collins ◽  
Jing Yu ◽  
...  
Keyword(s):  
Process Planning ◽  
Computer Aided Design ◽  
Complex Geometry ◽  
Geometric Constraints ◽  
Machining Process ◽  
Layer By Layer ◽  
User Input ◽  
Computer Aided ◽  
Subtractive Manufacturing ◽  
The Creation

Direct digital manufacturing (DDM) is the creation of a physical part directly from a computer-aided design (CAD) model with minimal process planning and is typically applied to additive manufacturing (AM) processes to fabricate complex geometry. AM is preferred for DDM because of its minimal user input requirements; as a result, users can focus on exploiting other advantages of AM, such as the creation of intricate mechanisms that require no assembly after fabrication. Such assembly free mechanisms can be created using DDM during a single build process. In contrast, subtractive manufacturing (SM) enables the creation of higher strength parts that do not suffer from the material anisotropy inherent in AM. However, process planning for SM is more difficult than it is for AM due to geometric constraints imposed by the machining process; thus, the application of SM to the fabrication of assembly free mechanisms is challenging. This research describes a voxel-based computer-aided manufacturing (CAM) system that enables direct digital subtractive manufacturing (DDSM) of an assembly free mechanism. Process planning for SM involves voxel-by-voxel removal of material in the same way that an AM process consists of layer-by-layer addition of material. The voxelized CAM system minimizes user input by automatically generating toolpaths based on an analysis of accessible material to remove for a certain clearance in the mechanism's assembled state. The DDSM process is validated and compared to AM using case studies of the manufacture of two assembly free ball-in-socket mechanisms.

Selection of Part Orientation for Multi-Axis Hybrid Manufacturing Process

2009 ◽  
Author(s):  
Jianzhong Ruan ◽  
Jun Zhang ◽  
Frank Liou
Keyword(s):  
Manufacturing Process ◽  
Search Space ◽  
Deposition Process ◽  
Hybrid Manufacturing ◽  
Optimal Orientation ◽  
Multi Stage ◽  
Build Time ◽  
Speed Up ◽  
Computation Algorithm ◽  
Selection Of

In regular 3 axis layered manufacturing processes, the build direction is fixed throughout the process. Multi-axis laser (more than 3-axis motion) deposition process, the orientation of the part can affect the non-support buildability in the multi-axis hybrid manufacturing process. However, each orientation that satisfies the buildability and other constraints may not be unique. In this case, the final optimal orientation is determined based on build time. The build time computation algorithm for multi-axis hybrid system is presented in this paper. To speed up the exhaustive search for the optimal orientation, a multi-stage algorithm is developed to reduce the search space.

Study on Models of Planning and Scheduling in IT Manufacturing Processes

2010 ◽  
Vol 20-23 ◽  
pp. 28-33
Author(s):  
Da Wei Liu ◽  
Hong Bin Liu
Keyword(s):  
Process Planning ◽  
Manufacturing Process ◽  
Manufacturing System ◽  
Manufacturing Processes ◽  
Key Factors ◽  
Integration Model ◽  
Planning And Scheduling ◽  
Process Plans ◽  
Manufacturing Process Planning

Traditionally, Models of IT manufacturing process planning and scheduling were carried out in a sequential way, where scheduling was done after process plans had been delivered. Since the two functions are usually complementary, it is necessary to integrate them correctly so that performance of an IT manufacturing system can be improved efficiently. In the thesis, a new integration model focused on key factors has been developed to facilitate the integration and optimization. The practice of the models show that the proposed approaches are promising and very effective methods for the integration of process planning and scheduling in IT manufacturing processes.

Characteristics of Laser Aided Direct Metal Powder Deposition Process for Nickel-Based Superalloy

2007 ◽  
Vol 534-536 ◽  
pp. 457-460 ◽  
Author(s):  
Kai Zhang ◽  
Wei Jun Liu ◽  
Xiao Feng Shang
Keyword(s):  
Computer Aided Design ◽  
Manufacturing System ◽  
Deposition Process ◽  
Advanced Technology ◽  
Rapid Manufacturing ◽  
Nickel Based Superalloy ◽  
Powder Deposition ◽  
Metallic Parts ◽  
Aided Design ◽  
Lower Production

Laser additive direct deposition of metals is a new rapid manufacturing technology, which combines with computer aided design, laser cladding and rapid prototyping. The advanced technology can build fully-dense metal components directly from CAD files without a mould or tool. With this technology, a promising rapid manufacturing system called “Laser Metal Deposition Shaping (LMDS)” is being constructed and developed. Through the LMDS technology, fully-dense and near-net shaped metallic parts can be directly obtained through melting coaxially fed powder with a laser. In addition, the microstructure and mechanical properties of the as-formed samples were tested and analyzed synthetically. The results showed significant processing flexibility with the LMDS system over conventional processing capabilities was recognized, with potentially lower production cost, higher quality components, and shorter lead time.

Laser Metal Deposition Process

3D Printing ◽  
2017 ◽  
pp. 172-182 ◽  
Author(s):  
Rasheedat M. Mahamood
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Computer Aided Design ◽  
Experimental Studies ◽  
Deposition Process ◽  
Metal Deposition ◽  
Functionally Graded ◽  
Laser Metal Deposition ◽  
Graded Material ◽  
Directed Energy

Laser metal deposition process belongs to the directed energy deposition class of additive manufacturing process that is capable of producing highly complex part directly from the three dimensional (3D) computer aided design file of the component by adding materials layer after layers. Laser metal deposition process is a very important additive manufacturing process and it is the only class of additive manufacturing process that can be used to repair valued component parts which were not repairable in the past. Also because this additive manufacturing process can handle multiple materials simultaneously, it is used to produce part with functionally graded material. Some of the features of the laser metal deposition process are described in this chapter. Some experimental studies on the laser metal deposition of Titanium alloy- composite are also presented.

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