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Abstract
With the integration of multiaxis layered manufacturing and material removal (machining) processes, a hybrid system has more capability and flexibility to build complicated geometry with a single setup. Process planning to integrate the two different processes is a key issue. In this paper, an algorithm of adaptive slicing for a five-axis Laser Aided Manufacturing Process (LAMP) is summarized that can generate uniform and non-uniform thickness slices. A method to build a non-uniform (thickness) layer that utilizes two processes is presented, and an overall algorithm for integration is described. The newly developed algorithm implemented in the process planning helps the hybrid system build parts more efficiently.
Keywords: Layered Manufacturing, Hybrid System, Process Planning, Toolpath Generation
Introduction
Due to global market competition, manufacturing companies are pressured as never before to develop new products as product life cycles shorten. This trend can be seen in almost all manufacturing companies in the world. The science and technologies that can greatly reduce time to market will be critical for any company to be competitive in the 21st century. Since its appearance in the mid 1980s, Layered Manufacturing (LM) has given industry an approach to achieve the goal of providing better quality products in a shorter time and at a lower cost. This process quickly produces a part by depositing material on substrates, layer by layer, directly from a CAD model.
Recently, the focus of researchers has shifted to metal direct deposition systems to obtain fully functional parts. A high-powered laser is utilized in the process to melt metal powder, layer by layer, to form an expected geometry. Laser-engineered net shaping (LENS) (Keicher et al. 1998) and the directed light fabrication (DLF) system (Milewski et al. 1998) were developed at Sandia National Laboratory and Los Alamos National Laboratory, respectively. Mazumder et al. (1997) has also conducted research on metal-related forming systems. One of the primary disadvantages of a metal deposition system is that the accuracy and surface quality may not be adequate. The surface finish for a LENS fabricated part without additional processing is about 432 µ inches. Although LENS utilizes a laser-glazing technique to improve the surface finish to 74 µ inches, the processing speed is slow.
In a conventional 2.5-D laser deposition process, another major concern...