Xinhong Xiong, Zhang Haiou and Wang Guilan
The purpose of this paper is to develop a novel hybrid plasma deposition and milling (HPDM). For solving the bottleneck problem of low‐surface quality in existing direct rapid…
Abstract
Purpose
The purpose of this paper is to develop a novel hybrid plasma deposition and milling (HPDM). For solving the bottleneck problem of low‐surface quality in existing direct rapid metal prototyping technologies.
Design/methodology/approach
HPDM uses plasma deposition as an additive and conventional milling as subtractive technique, which synthesizes the advantages of both processes. Compared to other laser or electron beam deposition processes, plasma deposition used in HPDM is one of the most economic ways of depositing metals, CNC assisted to ensure the precision of the manufactured parts simultaneity.
Findings
This paper focus on the experimental investigation to find the basic process characteristics, the optimization of the process parameters such as transferred arc current, workpiece's speed, powder flow rate and feed per tooth using a statistical approach. Some metal parts, for instance, metal torsional vane, are then trial‐manufactured.
Research limitations/implications
The manufacturing cycle of HPDM is longer than simplex direct metal rapid prototyping, and the surface accuracy should be further investigated.
Practical implications
HPDM is a very useful and effective method to manufacture metal parts with fine surface state directly.
Originality/value
This paper describes a novel process and manufacturing system for fabrication metal prototyping direct, which can improve the inside and outside quality of the metal rapid prototypes.
Details
Keywords
Guanchen Liu, Dongdong Xu, Zifu Shen, Hongjie Xu and Liang Ding
As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous…
Abstract
Purpose
As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.
Design/methodology/approach
Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.
Findings
In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.
Originality/value
With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.
Details
Keywords
K.P. Karunakaran, Alain Bernard, S. Suryakumar, Lucas Dembinski and Georges Taillandier
The purpose of this paper is to review additive and/or subtractive manufacturing methods for metallic objects and their gradual evolution from prototyping tools to rapid…
Abstract
Purpose
The purpose of this paper is to review additive and/or subtractive manufacturing methods for metallic objects and their gradual evolution from prototyping tools to rapid manufacture of actual parts.
Design/methodology/approach
Various existing rapid manufacturing (RM) methods have been classified into six groups, namely, CNC machining laminated manufacturing, powder‐bed technologies, deposition technologies, hybrid technologies and rapid casting technologies and discussed in detail. The RM methods have been further classified, based on criteria such as material, raw material form, energy source, etc. The process capabilities springing from these classifications are captured in the form of a table, which acts as a database.
Findings
Due to the approximation in RM in exchange for total automation, a variety of multi‐faceted and hybrid approaches has to be adopted. This study helps in choosing the appropriate RM process among these myriad technologies.
Originality/value
This review facilitates identification of appropriate RM process for a given situation and sets the framework for design for RM.