The Combination of the Addition and Material Reduction Processes Is Used for Mixed Processing

The combination of material addition and material reduction produces far more effects than any other technology, but the current exploration of this new field is far from enough.

In most cases, the refining and reprocessing of the components manufactured by the addition is done on another device. Components produced through a directional energy deposition technology (or powder bed melting process) system are transferred to a computer nuutical control system (milling machine or machine tool) for subsequent machining and finishing. Imagine how difficult it is to determine the reference points, reference points, and tool paths for components on computer CNC machines, especially if the components are separated from the manufacturing disk. Designers and engineers can label positioning features and reference points on components to help determine the direction of the components and the reference points for machining.

At the same time, manufacturing is also moving towards the integration of material addition and material reduction processes with a single system, such as hybrid manufacturing. Several commercial systems have also been introduced on the market. DmG MORI, for example, integrates directional energy deposition technology (DED) (powder ineration and laser) with the capabilities of a five-axis computer CNC machine into a hybrid manufacturing system. In addition, Matsuura and Sodick are integrating powder bed melting processes and computer CNC capabilities into the company's hybrid manufacturing systems in different ways. DMG MORI officially introduced their powder bed melting process and computer CNC hybrid manufacturing system to the public. Of course, if customers can also choose the Ambit Powder Feed Laser Deposition Head from Hybrid Manufacturing Technologies to retrofit an existing computer CNC processing center, or use 3D mixing technology to combine powder and wire feed capabilities with your company's computer CNC machines. In the above way, the ordinary material reduction system can be transformed into a hybrid manufacturing system with relatively lower cost and energy.

Fortunately, DMG MORI's Lasttec 65 hybrid manufacturing system was installed in CIMM-3D, Penn State's metal booster manufacturing laboratory. This system is superior to all laboratory equipment, the laser-based powder feed system produces spot sizes of 1.5mm or 3mm, and the deposition of 10 to 15lb materials can be completed in 1h. At the same time, the user can use the capabilities of the five-axis computer CNC system to process the deposited material, or in the deposition process, to promote the material in different directions. In this way, support structures are omitted and more complex geometry is achieved within the maximum range of movement and rotation. Through the nozzle, the customer can see the material addition and decrease process during component manufacturing. The system is paired with a double powder feeder to ensure that the customer performs functional edration of the component by changing the material components during material deposition.

In addition to the powerful combination of material addition and material reduction manufacturing in hybrid manufacturing systems, further learning of this technology is required. For example, what is the optimal order of material addition and decrease? Will the toolpath planning software perform material reduction feature conflict detection after adding component features? In addition, how should the dimensional integrity of the machining surface be maintained when new materials are added and the heating components cause the components to deform? During material reduction, when the part is continuously flushed with the same cutting fluid, which cutting fluid should be selected to ensure that the newly added features can be cooled quickly, and how does the heating/cooling cycle affect the microstruct and mechanical characteristics of the component? Finally, what is the powder capture rate in each direction? Will it change as the part rotates around one of the five axes? What is the extent of powder capture and reuse? Obviously, the powder will not be recycled after rinsing the outer surface of the work piece with coolant.

At present, there are many professionals and people interested in the manufacture of add-ons are learning the details of the material manufacturing in the field of metalworking, but how to increase and reduce the material to optimize the mixing manufacturing process. The combination of the two produces far more effects than any other technology, but we have never explored this new area of hybrid manufacturing.