Investigation of Advanced Methods and Strategies for Hybrid Manufacturing Process Planning

Date

2024-3

Author

Dilberoğlu, Mecid Uğur

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Additive manufacturing (AM) often leads to parts with suboptimal surface quality and poor dimensional accuracy due to the nature of the layer-wise production technique. This issue is especially pronounced in material extrusion based additive manufacturing technology, where challenges such as surface staircase effects and the quality of internal features are prevalent. Hybrid additive manufacturing, which combines additive and subtractive manufacturing processes, presents a promising solution. It aims to enhance surface quality and dimensional accuracy by integrating material extrusion with precision subtractive milling in a single, streamlined process. This dissertation focuses on developing novel process planning methods for additive/subtractive hybrid manufacturing, specifically targeting the integration of fused filament fabrication (FFF) and milling. The study first aims to understand the fundamentals of the steps involved in hybrid additive manufacturing and explore the capabilities of the developed hybrid manufacturing platform. With the developed foundation, the researcher suggested an optimal way to apply milling to FFF parts and quantified the impact of the secondary processing on the part's surface quality. The main target of the study is to create advanced tool path and process-planning strategies for hybrid AM and evaluate them through virtual test cases and experiments carried out on the established platform.

Subject Keywords

Additive, Subtractive, Hybrid, Manufacturing, Fused filament fabrication, Milling

URI

https://hdl.handle.net/11511/109208

Collections

Graduate School of Natural and Applied Sciences, Thesis