The Hybrid Manufacturing is the blend of subtractive and additive manufacturing processes. Additive manufacturing processes have seen nowadays as an upward trend in complex and structurally sound industrial applications. At the same time, there is still an open ground in modeling and simulation techniques when applied to these processes. There are many fabrication processes in modern manufacturing, but current modeling and simulation tools only simulate a few unit processes based on different geometry models. To overcome the problem between different models, this paper studies various in-process geometry models together with their working systems for traditional manufacturing processes. Novel hybrid 5 axis multiple machining, 5 axis laser cladding, and layered manufacturing processes are presented to identify critical issues. Working towards a vision of pervasive modeling and simulation, a unified deformable in-process geometry model and simulation for 5 axis multiple machining, 5 axis laser cladding, and layered manufacturing simulations is developed and discussed.

1. Unified Model and Simulation of
Hybrid Manufacturing Processes
Mr. Liu Peiling
Principal Research Engineer
Singapore Institute of Manufacturing Technology
71 Nanyang Drive, Singapore 638075
Tel: 65-67938356 Mobile: 65-90123598 Fax: 65-67916377
plliu@simtech.a-star.edu.sg http://simtech.a-star.edu.sg

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Hybrid Manufacturing
The Hybrid Manufacturing is the blend of
subtractive and additive manufacturing
processes.
Additive manufacturing processes have seen
nowadays as an upward trend in complex and
structurally sound industrial applications.
At the same time, there is still an open ground in
modelling and simulation techniques when
applied to these processes.

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Commercial Solutions
A quick reuse of conventional material removal model
without an realistic additive features
Simplified deposition
track road shape
Mike Nicholson, Sales & Marketing Director of MachineWorks
says, "We have always been able to deliver material addition as
well as material removal but recently we have seen the
demand for additive simulation rocketing".

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Our solutions:
A unified hybrid manufacturing model
Multiple materials and surface textures
 Composite, surface painting, marking, ……
Multiple processes
 3-5 axis machining
 2.5 axis 3D printing, such as SLA, SLS, LOM,……
 3-5 axis cladding, welding……

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5 Axis Cladding
Nozzle Perpendicular to Deposition

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Deposition Track Road Shape
Melting Pot Simulation

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Start 5 Axis Machining

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5 Axis Flank Milling

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Clear Surface Details

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Multiple Material Deposition
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Test Case Vase

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5 Axis Cladding on Blade Tip
Import a scanned blade model in STL format
Automatic generate 3 axis milling, 3-5 axis
cladding and 5 axis machining toolpath
Simulate 3 axis milling to remove the tip
Simulate 3-5 axis cladding to build the tip
Simulate 5 axis machining to clean the
remaining stock

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Cut off Damaged Blade Tip

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3 Axis Cladding on Blade Tip

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5 Axis Cladding on Blade

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5 Axis Milling to Clear Remains

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5 Axis Milling to Clear Remains

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Finishing with 5 Axis Milling

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5 Axis Cladding on Blade Tip

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Higher Precision Finishing

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5 Axis Machining Simulation

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Start to Cut

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Roughing within 3 Minutes

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Toolpath and in Process Model

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Finishing with Multiple Operations

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Zoom In Details

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See from Another Angle

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Industry Strength Application

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Summary
Unified hybrid manufacturing model
Multiple materials and processes simulation
Cladding track road shape
Ten times faster than NX 3D simulation
 Voxel model based simulation
 Swept volume speeding algorithm
 Toolpath modeling and simulation
Automatic generation of 5 axis toolpath