The development of a novel process planning algorithm for an unconstrained hybrid manufacturing process

The application of state of the art manufacturing processes has always been constrained by the capabilities either from technical limitations such as limited materials and complex part geometries or production costs. As a result, hybrid manufacturing processes - where varied manufacturing operations are carried out - are emerging as a potential evolution for current manufacturing technologies. However, process planning methods capable of effectively utilising manufacturing resources for hybrid processes are currently limited. In this paper, a hybrid process, entitled iAtractive, combining additive, subtractive and inspection processes, along with part specific process planning is proposed. The iAtractive process aims to accurately manufacture complex geometries without being constrained by the capability of individual additive and subtractive processes. This process planning algorithm enables a part to be manufactured taking into consideration, process capabilities, production time and material consumption. This approach is also adapted for the remanufacture of existing parts. Four test parts have been manufactured from zero and existing parts, demonstrating the efficacy of the proposed hybrid process and the process planning algorithm. (C) 2013 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.