Hybrid manufacturing: a review of the synergy between directed energy deposition and subtractive processes
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ORIGINAL ARTICLE
Hybrid manufacturing: a review of the synergy between directed energy deposition and subtractive processes 1 ´ Jose´ Luis Davila 1 Lopes da Silva
· Paulo Inforc¸atti Neto1 · Pedro Yoshito Noritomi1 · Reginaldo Teixeira Coelho2 · Jorge Vicente
Received: 23 June 2020 / Accepted: 7 September 2020 / Published online: 22 September 2020 © Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Additive manufacturing (AM) is one of the pillars of Industry 4.0, where automation to create smart factories is the main target. The hybridization of processes is one of the leading strategies to implement a more flexible, efficient, and interconnected manufacturing environment. Nowadays, different researches are focused on the hybridization of metal AM and subtractive manufacturing (SM). Based on the working principles of AM and SM, it can be established that they are complementary processes. Hence, a synergy between them allows conceiving a unique process. As a result, the advantages are magnified, and the limitations of each one are minimized or eliminated. This review presents the latest developments, challenges, limitations, and future perspectives for the integration between directed energy deposition (DED) and SM. DED is a versatile AM process for metal parts fabrication, where the geometrical complexity is its main advantage. Nevertheless, the low surface quality and the difficult dimensional control of the parts create the need for post-processing. Traditional post-processing involves a higher production time, and the barriers cannot be completely overcome. Then, a hybrid process constitutes a powerful concept to combine both technologies efficiently, to produce complex parts with less waste of material and energy. Keywords Hybrid manufacturing · Additive manufacturing (AM) · Subtractive manufacturing (SM) · Directed energy deposition (DED) · Industry 4.0
1 Introduction Additive manufacturing (AM) groups a set of processes in which materials are joined layer upon layer to form parts; its working principle is opposite to that used in subtractive manufacturing (SM) [1–5], which creates the possibility of making them complementary [6]. Additive manufacturing had progressively evolved since its origin, when the focus
Jos´e Luis D´avila
[email protected] Jorge Vicente Lopes da Silva [email protected] 1
Nucleus of Three–Dimensional Technologies (NT3D), Center for Information Technology “Renato Archer” (CTI), Campinas, 13069-901, Brazil
2
Nucleus for Advanced Manufacturing (NUMA), School of Engineering of S˜ao Carlos (EESC), University of S˜ao Paulo (USP), S˜ao Carlos, 13566-590, Brazil
was on prototypes’ fabrication [7]. Nowadays, AM allows the fabrication of completely functional parts. All this evolution had taken place independently of subtractive processes [8]. These latter are mainly employed as postprocesses, principally for metallic materials. AM technology enables the fabrication of complex parts minimizing material waste. For metals, defects such as distortions, residual
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