A novel wire arc additive and subtractive hybrid manufacturing process optimization method

Abstract

A reasonable process plan is an important basis for implementing wire arc additive and subtractive hybrid manufacturing (ASHM), and a new optimization method is proposed. Firstly, the target parts and machining tools are modeled by level set functions. Secondly, the mathematical model of the additive direction optimization problem is established, and an improved particle swarm optimization algorithm is designed to decide the best additive direction. Then, the two-step strategy is used to plan the hybrid manufacturing alternating sequence. The target parts are directly divided into various processing regions; each processing region is optimized based on manufacturability and manufacturing efficiency, and the optimal hybrid manufacturing alternating sequence is obtained by merging some processing regions. Finally, the method is used to outline the process plan of the designed example model and applied to the actual hybrid manufacturing process of the model. The manufacturing result shows that the method can meet the main considerations in hybrid manufacturing. In addition, the degree of automation of process planning is high, and the dependence on manual intervention is low.

Keywords

wire arc additive manufacturing / hybrid manufacturing / process optimization / manufacturability

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Funding

National Natural Science Foundation of China(52305381); Natural Science Foundation of Jiangsu Province(BK20210351); Fundamental Research Funds for the Central Universities(30923011008)