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Energy consumption modeling of additive-subtractive hybrid manufacturing based on cladding head moving state and deposition efficiency

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Abstract

Additive-subtractive hybrid manufacturing (ASHM) process consumes a large amount of electrical energy during the processing stage due to the low process rate and high energy density. A reliable prediction of energy consumption is the starting point to develop potential energy-saving strategies. However, the power consumption characteristics of ASHM system are dynamic due to the non-continuous moving path and non-uniform moving speed of the cladding head. Besides, the cutting allowance of each sub-cutting process is fragmented and hard to be obtained because of the multiple alternate characteristics of the additive manufacturing (AM) and subtractive manufacturing (SM) during the processing stage. This paper proposed a combined energy consumption model based on process characteristics, which consists of a state-based AM energy consumption model and a cutting allowance-based SM energy consumption model. At AM stage, the energy consumption is classified into the deposition energy consumption, rapid moving energy consumption, and pause energy consumption based on the cladding head moving state. The power in each moving state is identified by the working statuses of machine sub-systems, and the duration is related to the length of moving path, number of inflection points, as well as the scanning speed. At SM stage, the deposition efficiency was introduced to characterize the volume fraction of total cutting allowance for machining the deposited part, and the energy consumption model is extrapolated as a function of the deposition efficiency and specific energy consumption (SEC). Experimental results show that the model could offer the prediction of energy consumption with an accuracy of more than 97%, and the breakdown analysis demonstrated that the AM energy consumption accounts for more than 80% of the whole ASHM energy consumption. It is recommended to increase the scanning speed and process rate under the premise of ensuring good forming quality to reduce the total ASHM energy consumption.

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Data availability

All data needed to evaluate the conclusions in the paper are present. Additional data related to this paper are available from the corresponding authors upon reasonable requests.

Abbreviations

AM:

Additive manufacturing

SM:

Subtractive manufacturing

ASHM:

Additive-subtractive hybrid manufacturing

LDED:

Laser-directed energy deposition

SLM:

Selective laser melting

SLS:

Selective laser sintering

FDM:

Fused deposition modeling

E total :

The total energy consumption of ASHM process (MJ)

E additive :

The energy consumption of AM process (MJ)

E subtractive :

The energy consumption of SM process (MJ)

E exchange_up :

The energy consumption when the cladding head replaces cutting tool (MJ)

E exchange_down :

The energy consumption when the cutting tool replaces cladding head (MJ)

E deposition :

The energy consumption of deposition state in AM (MJ)

E rapid :

The energy consumption of rapid moving state in AM (MJ)

E pause :

The energy consumption of pause state in AM (MJ)

P standby_mahcine tool :

The standby power of machine tool (W)

P standby_laser :

The standby power of laser machine (W)

P standby_chiller :

The standby power of laser chiller machine (W)

P powder :

The power required to drive the stepping motor of powder feeder (W)

P working_laser :

The power required to emit the laser beam (W)

P working_chiller :

The power required to drive the fan of laser chiller machine (W)

P feed :

The feed power of machine tool (W)

P fast_feed :

The fast feed power of machine tool (W)

m ASHM :

The mass of the ASHM part (g)

m depositon :

The mass of the deposited part (g)

L deposition :

The length of the deposition path (mm)

L rapid moving :

The length of the rapid moving path (mm)

t deposition :

The time in deposition state (s)

t rapid :

The time in rapid moving state (s)

Δt pause :

The duration of each pause (s)

n pause :

The number of pauses

N up :

The number of up exchange process

N down :

The number of down exchange process

k chiller :

The ratio of the deposition time to the working time of chiller fan

P output :

The laser output power (W)

v s :

The scanning speed (mm/min)

v f :

The powder feed rate (g/min)

ρ mat :

The material density (g/mm3)

η deposition :

The deposition efficiency (%)

MRR :

The material removal rate in SM (mm3/min)

PR :

The process rate in AM (g/min)

SEC :

Specific energy consumption (J/mm3)

SPE :

Specific printing energy (MJ/kg)

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Funding

This work was supported by National Natural Science Foundation of China (Grant No. 51975205) and the Natural Science Foundation of Hunan Province, China (Grant No. 2020JJ4202). Their financial contributions are gratefully acknowledged.

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Authors and Affiliations

  1. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha, 410082, People’s Republic of China

    Wen Liu, Haiying Wei, Min Zhang, Yaoen Luo & Yi Zhang

  2. Key Laboratory for Intelligent Laser Manufacturing of Hunan Province, Hunan University, Changsha, 410082, People’s Republic of China

    Wen Liu, Haiying Wei, Min Zhang, Yaoen Luo & Yi Zhang

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  1. Wen Liu
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  3. Min Zhang
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Contributions

Wen Liu designed and drafted the manuscript, Haiying Wei conceived the project and organized the paper, Min Zhang designed the verification method, Yaoen Luo performed the experiments and recorded the data, Wen Liu and Min Zhang analyzed the data, and Yi Zhang contributed to overall evaluation and revised the paper. All authors read and approved the manuscript.

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Correspondence to Haiying Wei.

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Liu, W., Wei, H., Zhang, M. et al. Energy consumption modeling of additive-subtractive hybrid manufacturing based on cladding head moving state and deposition efficiency. Int J Adv Manuf Technol 120, 7755–7770 (2022). https://doi.org/10.1007/s00170-022-09265-2

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