Investigation on synergism between additive and subtractive manufacturing for curved thin-walled structure

ABSTRACT

Direct energy deposition (DED), as a flexible and economic manufacturing method, has drawn extensive attentions, whereas low surface quality and dimensional accuracy hinder its development. Hybrid manufacturing perfectly solves these problems without introducing additional positioning errors. In this study, we evaluate the effect of the synergies on the forming process of curved thin-walled structures in terms of procedure complexity, microstructures and mechanical properties. A multi-physics model is developed to simulate the DED process and provide guidance for the subsequent subtractive manufacturing (SM) process to better achieve the objective. The results demonstrate that the process procedure of the multiple-cycle hybrid manufacturing (MCHM) presents much more complex than the one-cycle hybrid manufacturing (OCHM). The grain size in the transition region of the MCHMed sample is refined, increasing the localised microhardness. However, the tensile strength and ductility of the MCHMed sample are found slightly lower than those of the OCHMed sample.

KEYWORDS:

• Hybrid manufacturing
• multi-physics modelling
• curved multi-layer deposition
• manufacturing strategy
• mechanical properties

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

This work was supported by National Natural Science Foundation of China: [Grant Number 51975112]; Fundamental Research Funds for Central Universities: [Grant Number N180305032]; Liaoning revitalization Talents Program: [Grant Number XLYC1807063]; Fundamental Research Funds for the Central Universities: [Grant Number N2103007].

Notes on contributors

Lida Zhu

Lida Zhu is a professor of Northeastern University.

Shuhao Wang

Shuhao Wang is currently a PhD candidate of Northeastern University.

Hao Lu

Hao Lu is currently a PhD candidate of Northeastern University.

Dongxing Qi

Dongxing Qi is currently an engineer of AECC Shenyang Engine Research Institute.

Dan Wang

Dan Wang is currently an engineer of AECC Shenyang Engine Research Institute.

Zhichao Yang

Zhichao Yang is currently a PhD candidate of Northeastern University.

Jinsheng Ning

Jinsheng Ning is currently a PhD candidate of Northeastern University.

Yichao Dun

Yichao Dun is currently a PhD candidate of Northeastern University.

Pengsheng Xue

Pengsheng Xue is currently a PhD candidate of Northeastern University.

Peihua Xu

Peihua Xu is currently a PhD candidate of Northeastern University.

Bo Xin

Bo Xin is an associate professor of Northeastern University.