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1

Opening new opportunities for aeronautic, naval and train large components realization with hybrid and twin manufacturing

Rauch Matthieu, Hascoet Jean-Yves

Journal of Machine Engineering

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2022

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Vol. 22, No. 4

5--20

EN

Additive Manufacturing (AM) consist in producing parts by depositing material in successive layers. These step-by-step processes proposes new innovative directions for high value components: complex geometries are accessible without strong efforts (such as hollow or lattice structures which dramatically reduce the component weight while keeping their at least similar mechanical properties), assemblies can be simplified, spare parts can be realized at demand... Hence, AM has benefitted from large research efforts over the last decade, almost all existing industrial sectors have benefitted from them. This paper introduces some opportunities and the associated challenges attached to Additive Manufacturing, to produce large metallic components for naval aeronautics and train industries. In particular, two innovative approaches are discussed in details: hybrid manufacturing and twin manufacturing. Hybrid manufacturing consists in integrating AM together with other processes for the realization of components, with the objective to benefit from the interests of each process while avoiding its drawbacks. Hence, AM can realize complex geometries or offer low buy-to-fly ratios while high speed machining generates very good surface properties (position, roughness). Processes can be carried out sequentially or simultaneously on the features to manufacture and finding the optimal manufacturing work plan can be challenging. The paper introduces some hybrid approaches developed in the laboratory. Twin manufacturing uses models and multiphysics simulation methods to create a digital clone of the process implementation within the manufacturing environment. Manufacturing preparation and optimization can be carried in the virtual workshop where various configurations and choices can be tested before being selected. To enhance its accuracy, the digital twin can also be fed by monitoring data captured during the process. Several digital twins developed in the laboratory are provided. The paper is illustrated with several proof-of-concept parts made with SLM, LMD, WAAM and hybrid approaches in the laboratory. Among them, a hollow propellers that has the same hydrodynamics efficiency for a reduced weight for the naval industry, an aircraft structural panel that demonstrates simplified assemblies increased performance/mass ratio, a train component that shows the ability to produce structural parts at demand.

2

The cross-correlation function in assessment of surface topography shaping by hybrid milling and burnishing

Dudzińska Sara, Grochała Daniel, Bachtiak-Radka Emilia

Mechanik

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2019

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R. 92, nr 12

798-801

EN

In world literature much attention is devoted not only to the conscious surface shaping, but also to many problems that can be encountered during surface measurement. The development of surface metrology tries to respond to many industrial needs and keep up with sophisticated production techniques. Nevertheless the estimation and comparison of surfaces after several successive treatments is still complicated. For this purpose, the authors proposed the use of a correlation function to evaluate milled and then burnished surfaces, which is an alternative instrument to the parametric evaluation of the surface topography. This method can directly give an answer, whether the technological process has been carried out as expected. The measurements were carried out using a multi-sensor AltiSurf A520 instrument, manufactured by Altimet, according to its own developed methodology.

PL

W literaturze światowej wiele uwagi poświęca się nie tylko świadomemu kształtowaniu powierzchni, lecz także licznym problemom, jakie można napotkać przy jej pomiarach. Choć rozwój metrologii powierzchni niezaprzeczalnie stara się odpowiadać na potrzeby środowiska przemysłowego i nadążać za coraz bardziej wyrafinowanymi technikami produkcyjnymi, to oszacowanie i porównanie powierzchni po kilku następujących po sobie zabiegach wciąż wydaje się skomplikowane. Właśnie dlatego autorzy zaproponowali wykorzystanie funkcji korelacji do oceny chropowatości 3D powierzchni frezowanych, a następnie nagniatanych, która może stanowić doskonałe uzupełnienie oceny parametrycznej. Funkcja korelacji wzajemnej może w sposób bezpośredni dać odpowiedź, czy proces technologiczny został przeprowadzony zgodnie z oczekiwaniami i wymaganym stanem chropowatości 3D. Pomiary przeprowadzono za pomocą wieloczujnikowego instrumentu AltiSurf A520, wyprodukowanego przez firmę Altimet, według własnej metodologii.

3

Inconel-steel functionally bimetal materials by hybrid directed energy deposition and thermal milling: Microstructure and mechanical properties

Li Pengfei, Gong Yadong, Xu Yunchao, Qi Yang, Sun Yao, Zhang Huan

Archives of Civil and Mechanical Engineering

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2019

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Vol. 19, no. 3

820--831

EN

Many engineering applications, particularly those in extreme environments, require com-ponents with properties that vary with location in the part. Functionally bimetal materials (FBM) that combine dissimilar materials, such as those with different density and thermal properties, provide a potential solution to this need. Directed energy deposition (DED) is convenient to fabricate all kinds of complicated parts and to clad different materials at specific locations. Milling can improve the surface quality and dimensional accuracy after DED. Hybrid DED and thermal milling manufacturing can fabricate FBMs and be applied to laser repair. This study used this new method to fabricate Inconel-steel FBM. Inconel 718 powder and 316L stainless steel powder were deposited on the thermal milling surface of parts prepared with DED. The interfacial characteristics of different cladding materials were compared. Microstructure, chemistry, phase composition, element segregation and micro-hardness varied with position and were characterized by energy dispersive spectroscopy, X-ray diffraction, scanning electron microscopy and microhardness testing. Finally, the tensile properties of the FBM were compared to other materials, and the fracture location and morphology were analyzed. The results showed that the yield strength (YS) reached 368 MPa, and the ultimate tensile strength (UTS) reached 516 MPa. The Vickers microhard-ness of the diffusion layer was approximately 250 HV.

4

Obróbka skrawaniem oraz techniki przyrostowe jako integralne etapy procesu wytwarzania hybrydowego z metali w Przemyśle 4.0

Królikowski M. A., Krawczyk M.B.

Mechanik

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2018

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R. 91, nr 8-9

769--771

PL

W artykule omówiono rolę procesu obróbki skrawaniem jako integralnego etapu wytwarzania elementów z metali z wykorzystaniem technik przyrostowych. Wytwarzanie przyrostowe AM (additive manufacturing) jest zaliczane do grupy technik Przemysłu 4.0, które zmienią oblicze przemysłu i w przyszłości będą podstawą produkcji hybrydowej. Niniejszy artykuł wskazuje, że wytwarzaniu przyrostowemu z metali towarzyszą prawie zawsze dodatkowe metody obróbki konwencjonalnej.

EN

This paper describes the role of metal cutting process as integral part of manufacturing with application of MAM (metal additive manufacturing) techniques. Additive manufacturing is written explicit as main feature included in Industry 4.0 cycle. AM techniques lead to hybrid manufacturing techniques as well. This paper points that AM almost always is accompanied by supplementary conventional machining.

5

Hybrid additive and subtractive manufacturing processes and systems: a review

Grzesik W.

Journal of Machine Engineering

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2018

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Vol. 18, No. 4

5--24

EN

This review paper highlights the hybrid manufacturing processes which integrate the additive and subtractive processes performing on one hybrid platform consisting of the LMD (laser metal deposition) unit and CNC machine tools. In particular, some important rules and advantages as well as technological potentials of the integration of different AM technique and finishing CNC machining operations are discussed and overviewed. Some representative examples such as formation of difficult features around the part periphery, deposition of functional layers and coatings and repair of high-value parts in aerospace industry are provided. Some conclusions and future trends in the implementation of hybrid processes are outlined.

6

Badania naprężeń w warstwie wierzchniej części kształtowanych w sposób hybrydowy

Dudzińska S., Grochała D., Bachtiak-Radka E.

Autobusy : technika, eksploatacja, systemy transportowe

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2018

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R. 19, nr 9

129--132

PL

W artykule omówiony został aspekt naprężęń w warstwie wierzchniej części kształtowanych w sposób hybrydowy, gdzie elementy są najpierw frezowane, a następnie nagniatane. Naprężenia w warstwie wierzchniej odgrywają bardzo ważną rolę, ponieważ są odpowiedzialne m.in. za rozwój pęknięć, korozję i kawitację. Charakteryzacja i badania naprężeń w warstwie wierzchniej umożliwiają predykcję zachowań części podczas eksploatacji. Podczas prowadzonych badań potwierdzono wprowadzenie korzystnych, ściskających naprężeń w warstwie wierzchniej. Dla różnych średnic kulek nagniatających odnotowano istotne różnice wartości naprężeń wywołane zmienną wartością nacisków przy tej samej wartości siły nagniatania Fn.

EN

In this paper was presented the aspect of stress in the top layer part shaped in a hybrid technology, where the elements are first milled and then burnished. Stresses in the surface layer play a very important role because they are responsible, among others, for the development of cracks, corrosion and cavitation. Characterization and stress research in the surface layer allow prediction of parts behavior exploitation. During the research was confirmed the being of positive, compressive stresses in the surface layer. For the different diameters of the burnishing balls there were significant differences in stress values due to the variable pressure value at the same value of the burnishing force Fn.