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The International Journal of Advanced Manufacturing Technology

Erschienen in:

04.05.2022 | ORIGINAL ARTICLE

Energy consumption modeling of additive-subtractive hybrid manufacturing based on cladding head moving state and deposition efficiency

verfasst von: Wen Liu, Haiying Wei, Min Zhang, Yaoen Luo, Yi Zhang

Erschienen in: The International Journal of Advanced Manufacturing Technology | Ausgabe 11-12/2022

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Abstract

Additive-subtractive hybrid manufacturing (ASHM) process consumes a large amount of electrical energy during the processing stage due to the low process rate and high energy density. A reliable prediction of energy consumption is the starting point to develop potential energy-saving strategies. However, the power consumption characteristics of ASHM system are dynamic due to the non-continuous moving path and non-uniform moving speed of the cladding head. Besides, the cutting allowance of each sub-cutting process is fragmented and hard to be obtained because of the multiple alternate characteristics of the additive manufacturing (AM) and subtractive manufacturing (SM) during the processing stage. This paper proposed a combined energy consumption model based on process characteristics, which consists of a state-based AM energy consumption model and a cutting allowance-based SM energy consumption model. At AM stage, the energy consumption is classified into the deposition energy consumption, rapid moving energy consumption, and pause energy consumption based on the cladding head moving state. The power in each moving state is identified by the working statuses of machine sub-systems, and the duration is related to the length of moving path, number of inflection points, as well as the scanning speed. At SM stage, the deposition efficiency was introduced to characterize the volume fraction of total cutting allowance for machining the deposited part, and the energy consumption model is extrapolated as a function of the deposition efficiency and specific energy consumption (SEC). Experimental results show that the model could offer the prediction of energy consumption with an accuracy of more than 97%, and the breakdown analysis demonstrated that the AM energy consumption accounts for more than 80% of the whole ASHM energy consumption. It is recommended to increase the scanning speed and process rate under the premise of ensuring good forming quality to reduce the total ASHM energy consumption.

Vorheriger Artikel Prediction of turning performances using an equivalent oblique cutting model

Nächster Artikel Optimizing the mean and variance of bead geometry in the wire + arc additive manufacturing using a desirability function method

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Titel: Energy consumption modeling of additive-subtractive hybrid manufacturing based on cladding head moving state and deposition efficiency
verfasst von: Wen Liu
Haiying Wei
Min Zhang
Yaoen Luo
Yi Zhang
Publikationsdatum: 04.05.2022
Verlag: Springer London
Erschienen in: The International Journal of Advanced Manufacturing Technology / Ausgabe 11-12/2022
Print ISSN: 0268-3768
Elektronische ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-022-09265-2

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