Review on Precision Control Technologies of Additive Manufacturing Hybrid Subtractive Process

doi:10.11900/0412.1961.2019.00053

Acta Metall Sin

2020, Vol. 56

Issue (1): 83-98 DOI: 10.11900/0412.1961.2019.00053

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Review on Precision Control Technologies of Additive Manufacturing Hybrid Subtractive Process

LU Zhenyang^1,²,TIAN Hongyu^1,³,CHEN Shujun¹(

),LI Fang¹

1. Engineering Research Center of Advanced Manufacturing Technology for Automotive Components-Ministry of Education, Beijing University of Technology, Beijing 100124, China
2. College of Robotics, Beijing Union University, Beijing 100101, China
3. Beijing Engineering Research Center of Smart Mechanical Innovation Design Service, Beijing 100020, China

Cite this article:

LU Zhenyang,TIAN Hongyu,CHEN Shujun,LI Fang. Review on Precision Control Technologies of Additive Manufacturing Hybrid Subtractive Process. Acta Metall Sin, 2020, 56(1): 83-98.

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Abstract

A hybrid technique of additive manufacturing and subtractive process has provided a new solution combining product design and control by software. Wire arc additive manufacturing (WAAM) process wins well-respected because of its low cost and high efficiency of deposition, nevertheless the process has its limitation of high heat input and low forming accuracy. A new process of additive manufacturing with high efficiency of modeling is urgent needed which can control heat transfer, mass transfer and force transfer. To overcome the disadvantage upon, various hybrid manufacturing techniques have been developed with high efficiency and controlled modeling in recently. The machining process in hybrid manufacturing has more different characteristics from traditional material removal processes, such as residual stress and heat in the blank. These influence the whole efficiency of the hybrid manufacturing. The primary aim of this paper is to explore the feasibility of thermal machining during this process and make rational use of additive manufacturing in order to obtain optimal accuracy.

Key words: wire arc additive manufacturing hybrid manufacturing process precision control

Received: 28 February 2019

ZTFLH:

TG409

Fund: National Natural Science Foundation of China(51475008);National Natural Science Foundation of China(51775007);China Postdoctoral Science Foundation(2017M610726);National Natural Science Foundation of China(2014ZX04001-171)

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	Zhenyang LU
	Hongyu TIAN
	Shujun CHEN
	Fang LI

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https://www.ams.org.cn/EN/10.11900/0412.1961.2019.00053 OR https://www.ams.org.cn/EN/Y2020/V56/I1/83

Fig.1 Schematic of the method (a) and manufacturing device (b) for wire arc additive manufacturing (WAAM) method

Fig.2 Case applications of WAAM^[10](a) wing of aircraft work-piece (b) outer rib supporting of undercarriage

Fig.3 Case applications and finished product of NTi Company using WAAM^[10]

Fig.4 Comparisons of integral panel structure and its manufacturing process (W_FR—wire-feed rate,T_S—travel speed, W_V—welding voltage, S_S—spindle speed, T_FR—tool-feed rate)^[11](a) integral panel structure (b) traditional milling process (c) WAAM hybrid milling process

Fig.5 Schematic diagram (a) and block diagram (b) of error transfer from WAAM to subtractive manufacturing process^[11]

Fig.6 Disturbance factors during WAAM(a) starting and ending point of welding arc^[13] (b) large curvature^[1] (c) intersection^[14] (d) deposition height^[15]

Fig.7 Forming morphology errors at corners and arcs^[19](a) plane shapes with sharp angle of about 20°, 15° and 10° respectively deposited using WAAM(b) curve shapes with curvature radii of about 20 mm, 10 mm and 5 mm respectively deposited using WAAM

Fig.8 Variation of forming morphology with deposition height^[25]

Fig.9 Schematic diagrams of bypass arc control process (GTAW—gas shielded tungsten arc welding, GMAW—gas metal arc welding)^[32](a) double electrode GMAW process (b) arcing-wire GTAW process

Table 1 Comparisons of several additive manufacturing methods of metal material

Sort	Technical principle	Limitation
Surface tension transition (STT)	To improve the energy accumulation of droplets, the welding current can be reduced instantaneously and the spatter can be effectively reduced before the droplet short circuit liquid bridge bursts	Short-circuit transition is required and robustness is insufficient
Pulse GMAW	Improving droplet energy accumulation, peak current transfer droplet and base dimension arc, reducing average heat input	The thermal input of the peak value of pulse impacts the substrate
Droplet excitation	Improving droplet energy accumulation, using droplet oscillation inertia force to promote droplet transition, reducing pulse peak current and improving transition robustness	Precise matching of droplet oscillation phase is required
Cold metal transfer (CMT)	By introducing mechanical force, the welding wire can be fed back and forth, the short-circuit droplets can be broken mechanically, there is no spatter transition, and the heat input is low	The dynamic performance of the motor is limited, and the torch is complex and bulky
Magnetic control GMAW	The external magnetic field is introduced to add Lorentz force to increase the transition frequency	The effect is weak
Bypass GMAW	By introducing the bypass arc with additional electromagnetic force, the droplet transition can be significantly promoted	Multi-electrode accessibility is limited, high arc length avoids arcing
Ultrasonic GMAW	Welding arc space composites ultrasonic field, while the ultrasonic radiation force promotes the droplet transition and the droplet transition is often under the longer arc	Droplet size can be controlled, but it is difficult to provide directivity
Laser enhancement GMAW	Laser evaporation reaction is introduced. Pulsed laser irradiates droplets. Laser impulse promotes droplet detachment and realizes controllable transition	The direction of evaporation reaction force is directly related to the surface morphology of droplets, so it is difficult to accurately control the direction of force

Table 2 Results of arc heat source droplet transfer control

Fig.10 Hybrid manufacturing system and its part^[18](a) one direct and two crossing method (b) finished part

Fig.11 Equivalent strain model with inherent strain method(k_s^{is the stiffness of spring element;^{k_R_x and k_R_y are the residual inherent strain equivalent stiffnesses on x-axis and y-axis, respectively;^{TG_x and TG_z are the temperature gradients on x-axis and z-axis, respectively)^[48]}}}

Fig.12 Numerical simulation of deformation (a, b) and stress (c, d) in additive hybrid subtractive manufacturing process (δ_top is the deformation on the top, and δ_max is the maximum deformation in the direction of altitude)^[55]

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