Predictive Manufacturing: Subtractive and Additive

Abstract

Manufacturing is the key to today’s industrial competitiveness, and it is broadly classified into two categories, subtractive and additive. In current study, the ability to predictively model manufacturing performance attributes in both categories is introduced. In subtractive manufacturing, modeling of laser-assisted and ultrasonic vibration-assisted milling are presented. In laser-assisted milling, the laser preheating temperature field is predicted, and the dynamic recrystallization as well as grain growth triggered under high temperature is considered, which enhances the accuracy of force and residual stress prediction. In ultrasonic vibration-assisted milling, the intermittent effect is considered through tool-workpiece separation criteria. And the force reduction in ultrasonic vibration-assisted milling is accurately predicted. In additive manufacturing, laser-assisted metal additive manufacturing is introduced. And the predictive modeling of temperature field in powder bed metal additive manufacturing is presented. The model considers heat transfer boundary including heat loss from convection and radiation at the part boundary. Through the comparison between measured and calculated molten pool dimensions, the model is proven to have high computational efficiency and high prediction accuracy.