Optimization of hybrid manufacturing process parameters by using FDM in CNC machine

Abstract

The major methods used for manufacturing new components in industries, are Subtractive and Additive Manufacturing (AM). Subtractive method is generally more accurate and precise, but it is intricate to reduce material wastage in subtractive manufacturing. In contrast, Additive Manufacturing can produce an object with convoluted features and allows the material to be used more proficiently. A filament extrusion base process which integrates Computer Numerical Control (CNC), Material Science and Computer Aided Design system inAdditive Manufacturing is Fused Deposition Method (FDM) technique.The FDM extrusion Process produces objective parts without geometrical restrictions. However, due to the irregular shrinkage, residual stress and Stair Case effect in AM product their accuracy is usually indecisive. Combining Subtractive Processes and Additive within a single workstation, In CNC machine attachment of FDM Extruder is designed to strap up the relative merits of each process and this hybridization facilitates to overcome the limitation of each individual process. These techniques present opportunities to improve utilization of material, part complexity, and quality management in functional components. In this paper, CNC Machine is used as a workstation to hybrid both processes. By working on specified controllable parameters like layer thickness, raster angle, depth of cut for optimization of whole process using parameters significance on the process for achieving the objective of the paper is the minimization of material waste and good surface finish. The technique used for the design of experiment and optimization of parameters is Taguchi Method with significance to S/N ratio. The proposed hybrid manufacturing process is achieving the less material wastage compare to the machining product.