Digital Twin in Process Planning of the Additive and Subtractive Process Chain for Laser Metal Deposition and Micro Milling of Stainless Steel

Research output: Contribution to journalArticleResearchpeer review

Authors

  • Berend Denkena
  • Marcel Wichmann
  • Talash Malek
  • Hai Nam Nguyen
  • Makoto Kato
  • Kaito Isshiki
  • Ryo Koike
  • Yasuhiro Kakinuma
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Details

Original languageEnglish
Article number071004
Number of pages11
JournalJournal of Manufacturing Science and Engineering
Volume146
Issue number7
Early online date21 May 2024
Publication statusPublished - Jul 2024

Abstract

Additive and subtractive (Add/Sub) manufacturing processes are increasingly being combined to produce complex parts with unique geometries and properties. However, the design of such combined processes is often challenging as it requires a deep understanding of the interaction between the different processes. On the other hand, digital twin (DT) technology has become a powerful tool in recent years for optimizing manufacturing processes. This article explores the use of the digital twin technology for a holistic process planning of combined additive and subtractive processes. The article describes the integration of laser metal deposition (LMD) and micro-milling prediction models of resulting geometry (width and height), hardness, and surface roughness into the digital twin. This is then used for combined process planning to achieve different target values regarding resulting geometry and surface roughness. For the planning of this combined process chain, further criteria such as tool life, energy, and process time are considered in the optimization, showing the potential for sustainable and efficient production. Sensorless cutting force estimation is also used to detect small cutting forces, with the potential to use this as a soft sensor for roughness estimation. The measured width, height, and roughness as a result of the process parameters suggested by the optimization algorithms showed a mean absolute percentage error (MAPE) of 4, 17, and 16%, respectively.

Keywords

    additive manufacturing, machining processes, modeling and simulation, process planning

ASJC Scopus subject areas

Cite this

Digital Twin in Process Planning of the Additive and Subtractive Process Chain for Laser Metal Deposition and Micro Milling of Stainless Steel. / Denkena, Berend; Wichmann, Marcel; Malek, Talash et al.
In: Journal of Manufacturing Science and Engineering, Vol. 146, No. 7, 071004, 07.2024.

Research output: Contribution to journalArticleResearchpeer review

Denkena B, Wichmann M, Malek T, Nguyen HN, Kato M, Isshiki K et al. Digital Twin in Process Planning of the Additive and Subtractive Process Chain for Laser Metal Deposition and Micro Milling of Stainless Steel. Journal of Manufacturing Science and Engineering. 2024 Jul;146(7):071004. Epub 2024 May 21. doi: 10.1115/1.4065415
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