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Material bead deposition with 2 + 2 ½ multi-axis machining process planning strategies with virtual verification for extruded geometry


Process planning for hybrid manufacturing, where additive operations can be interlaced with machining operations, is in its infancy. New plastic- and metal-based hybrid manufacturing systems are being developed that integrate both additive manufacturing (AM) and subtractive (machining) operations. This introduces new process planning challenges. The focus of this research is to explore process planning solution approaches when using a hybrid manufacturing approach. Concepts such as localized AM build ups, adding stock to a CAD model or section for subsequent removal, and machining an AM stock model are investigated and illustrated using virtual simulations. A case study using a hybrid laser cladding process is used to demonstrate the opportunities associated with a hybrid solution. However, unlike machining, the process characteristics from system to system vary greatly. These are portrayed via a high power, high material deposition feed rate laser cladding system. There are unique challenges associated with AM processes and hybrid manufacturing. New tools and design rules need to be developed for this manufacturing solution to reach its potential.

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This research is funded by the Ontario Center of Excellence Collaborative Research program, Natural Sciences and Engineering Research Council of Canada through the Discovery Grant, and MITACs. The authors would like to thank CAMufacturing Solutions Inc., and Optomec Inc. for the partial funding and resources they have provided for this research project.

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Correspondence to Ruth Jill Urbanic.

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Urbanic, R.J., Hedrick, R.W., Saquib, S. et al. Material bead deposition with 2 + 2 ½ multi-axis machining process planning strategies with virtual verification for extruded geometry. Int J Adv Manuf Technol 95, 3167–3184 (2018).

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  • Process planning
  • Additive manufacturing
  • Hybrid manufacturing
  • Virtual simulation
  • Bead geometry
  • Tool paths