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Research Papers

Integrated Process Planning for a Multiaxis Hybrid Manufacturing System

[+] Author and Article Information
Lan Ren

Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409maggie.lanren@gmail.com

Todd Sparks

Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409toddesparks@gmail.com

Jianzhong Ruan

Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409jzruan@mst.edu

Frank Liou

Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409liou@mst.edu

J. Manuf. Sci. Eng 132(2), 021006 (Mar 30, 2010) (7 pages) doi:10.1115/1.4001122 History: Received November 06, 2007; Revised January 19, 2010; Published March 30, 2010; Online March 30, 2010

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.

Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

Five-axis hybrid laser-aided manufacturing process

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Figure 2

Typical three-axis rapid manufacturing system

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Figure 3

Centroidal axis extractions (a) solid model (b) centroidal axis (c) centroidal axis with solid

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Figure 4

Decomposition results of a solid model

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Figure 5

Building relationship graph

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Figure 6

Collision occurs in deposition process between nozzle and the unfinished part (a) to-be-built part (b) building phase I (c) building phase II (d) building phase III, and (e) building phase IV (collision occurs)

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Figure 7

building sequence to avoid collision

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Figure 8

Slicing layers for every component

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Figure 9

CAD model of the deposit at different layers

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Figure 10

Flowchart of collision detection algorithm

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Figure 11

Offsetting tool path patterns (a) contour pattern (b) spiral pattern

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Figure 12

Zigzag tool path patterns along the (a) fixed direction and (b) interlaced direction

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Figure 13

Frequently occurring voids in the deposition process

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Figure 14

Adaptive toolpath to avoid deposition voids

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Figure 15

Examples of surface machining toolpath generation

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Figure 16

Hybrid manufacturing system in Missouri S&T LAMP laboratory

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Figure 17

Post-processing result with laser and powder control: (a) .TXT file (b) complete path

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Figure 18

Hybrid process planning software framework platform

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Figure 19

Hybrid manufacturing process

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