Structural Optimization of Additive/Subtractive Hybrid Machines

Abstract

In the recent fourth industrial revolution, the demand for additive processes has emerged rapidly in many mechanical industries, including the aircraft and automobile industries. Additive processes, in contrast to subtractive processes, can be used to produce complex-shaped products, such as three-dimensional cooling systems and aircraft parts that are difficult to produce using conventional production technologies. However, the limitations of additive processes include nonuniform surface quality, which necessitates the use of post-processing techniques such as subtractive methods and grinding. This has led to the need for hybrid machines that combine additive and subtractive processes. A hybrid machine uses additional additive and subtractive modules, so product deformation, for instance, deflection, is likely to occur. Therefore, structural analysis and design optimization of hybrid machines are essential because these defects cause multiple problems, such as reduced workpiece precision during processing. In this study, structural analysis was conducted before the development of an additive/subtractive hybrid processing machine. In addition, structural optimization was performed to improve the stability of the hybrid machine.