Abstract
Hybrid manufacturing, a combination of subtractive manufacturing (SM) and additive manufacturing (AM), is employed to fabricate complicated shapes and reduce the total process time. The process time of SM, such as the milling process, depends on the cutting tool. A long cutting tool is used for finishing complicated shapes to avoid collisions between the cutting tool and workpiece, but it increases the processing time. However, high-speed cutting conditions can be applied if a short cutting tool is used. However, this requires some alternation between AM and SM. For optimal process planning, the alternation sequence and process time should be estimated in advance. In this study, an SM process simulator and alternation-sequence proportion system was developed. This system can simulate the SM process and propose an alternation sequence while avoiding collisions during the SM process. In addition, the process time can be estimated using the system. Therefore, the system user can plan the hybrid manufacturing process by considering the total process time and alternation sequence. The verification-experiment results confirmed that two patterns of hybrid manufacturing were successfully conducted, and the process time could be estimated with high accuracy using the proposed system.
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