Research and Development of A Hybrid Rapid Manufacturing Process

This paper presents the research and development of a hybrid rapid manufacturing process being developed at the University of Missouri-Rolla. This process includes a laser deposition and a 5axis CNC milling system. By combining laser deposition and machining processes, the resulting hybrid process can provide greater build capability and better accuracy and surface finish. The hybrid process can build some features that are difficult to build in using a purely deposition processes. The issues and related approaches in the research and development of the hybrid deposition-machining process, including laser deposition process, system design and integration, process planning, and sensor selection and control, are discussed. Introduction This paper summarizes an interdisciplinary approach to design and develop a hybrid rapid manufacturing process to build functional metal parts. This process uses laser deposition for material deposition and CNC milling for material removal as shown in Figure 1. This five-axis laser deposition/CNC machining process has been developed at the Laser Aided Manufacturing Processes (LAMP) Laboratory in the University of Missouri at Rolla (UMR). It includes two major systems: a laser deposition system (Rofin–Sinar 025) and a CNC milling machine system (Fadal VMC3016L). The laser deposition system and CNC milling machine work in shifts in a five-axis motion mode. The laser deposition system consists of a laser and a powder feeder. In conventional 2.5-D laser deposition process to create three-dimensional parts, overhang and top surfaces of hollow parts need be supported. Often support materials for functional metal parts are not feasible. Moreover, deposition of the support material for metals leads to poor surface quality at the regions in contact with the support structure. Moreover, it increases the build time of the part and necessitates a time-consuming postprocessing. Additionally use of support increases the build time of the part and necessitates a time-consuming post-processing. With a five-axis deposition process integrated with five-axis machining, these obstacles can be removed. This paper summarizes the issues and related