A process planning framework and virtual representation for bead-based additive manufacturing processes

CNC-based hybrid manufacturing systems capable of additive manufacturing (AM) and machining have been developed for metal and large thermoplastic components. Currently, there are no CAD/CAM systems that seamlessly integrate additive and machining tool paths and simulation, as required for a complete...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2017-04, Vol.90 (1-4), p.361-376
Main Authors: Urbanic, R. J., Hedrick, R. W., Burford, C. G.
Format: Article
Language:English
Subjects:
Additive manufacturing
CAD/CAM
CAE) and Design
Computer simulation
Computer-Aided Engineering (CAD
Engineering
Hybrid systems
Industrial and Production Engineering
Laser beam cladding
Machining
Mechanical Engineering
Media Management
Modules
Numerical controls
Original Article
Path planning
Process planning
Simulation
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Summary:CNC-based hybrid manufacturing systems capable of additive manufacturing (AM) and machining have been developed for metal and large thermoplastic components. Currently, there are no CAD/CAM systems that seamlessly integrate additive and machining tool paths and simulation, as required for a complete hybrid manufacturing solution. Tool paths for bead-based AM cannot be generated by simply reversing the Z processing order of waterline machining tool paths. AM process planning modules are significantly different than those for machining. Unique AM process planning challenges related to geometry, establishing relevant process-specific settings, thermodynamics, tool path planning and realistic virtual process simulation are discussed. To support hybrid manufacturing, the output from the additive manufacturing simulation must be employed as a stock model for subsequent machining. This paper discusses the architecture, process and data flows for a bead-based AM processes, with results being presented primarily for laser cladding.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-016-9392-8