Modeling and Process Planning Tool for Hybrid Metal Additive/Subtractive Manufacturing to Control Residual Stress and Reduce Distortion

The key innovation this project seeks to advance is a framework by which the complex stress states produced by hybrid additive manufacturing (AM) / subtractive manufacturing (SM) processes can be addressed. The optimization algorithm begins with segmenting the model geometry into a set of hybrid features. ĀFor the purposes of this model, we are defining a hybrid feature as geometry we can produce by 1 AM operation followed by 1 SM operation. ĀComplex geometries can be accomplished by iterating the algorithm over a set of hybrid features. ĀPredictions of the part material's residual stresses, internal temperature, and geometry are tracked within the path plan's data structure as the optimizer proceeds. ĀA set of physics-inform and geometric surrogate models created by both PINE and our project partner organizations provide guidance on path planning strategy and parameter selection within the optimization loop. ĀAdditionally, this data could be warehoused for future digital twin applications, which could be particularly useful for repair activities on a component.