HYBRID

MANUFACTURING

Presented by: Pratyay

Choudhury
M.E (Mechanical)
18-913
II Sem ( I yr)
UIET, PU
Chandigarh
 Contents
 Introduction
 Existing technology
 Fusion of additive and subtractive
machining
 Meaning of hybrid manufacturing
 Laser assisted machining
 Magnetic -field assisted machining
 Electro-chemical discharge machining
 Mechano-electrochemical maching
 Merits
 Applications
Introduction
 Along with the advent of 21st century, various
manufacturing processes have been widely used
for manufacturing for multiple industrial sectors.
 These processes include CNC machining, additive
manufacturing which have transformed the face of
modern manufacturing industry.

 However these orthodox manufacturing processes

have some inherent problems associated with
them like excessive mechanical contact between
the parts and heat loss etc.
Basic principle of Hybrid
manufacturing
A hybrid manufacturing process combines
two or more established advance
manufacturing processes into a new
combined set-up . The reason for such a
combination and the development of a
hybrid machining process is mainly to
make use of the combined advantages and
to avoid or reduce some adverse effects
the constituent processes produce when
they are individually applied.
WHAT IS HYBRID
MANUFACTURING

Imagine the scope!!

If there are ‘n’

established
manufacturing
processes, No. of
possible Hybrid
manufacturing
processes =
nC2+nC3……..+nCn
Existing technologies
1) Additive manufacturing:
Traditional manufacturing methods involve a
material being carved or shaped into the
desired product by parts of it being removed in
a variety of ways.
Additive manufacturing is the pole opposite;
structures are made by the addition of
thousands of minuscule layers which combine
to create the product. The process involves the
use of a computer and special CAD software
which can relay messages to the printer so it
“prints” in the desired shape.
2) Subtractive manufacturing:

A decades-old technique, subtractive manufacturing

(computer numerical control, or CNC machining) is
a tried-and-true manufacturing method used to
produce a huge range of products for a wide
variety of industries. The term “subtractive” is apt,
as the machining process involves subtracting
materials in order to produce an end product. A
number of new industrial manufacturing processes
have become popular over the last several years,
but subtractive manufacturing still remains the
most common method.
FUSION OF ADDITIVE AND
SUBTRACTIVE MANUFACTURING
• Additive and subtractive methodologies have
always been viewed as two opposite options
with criteria of decision being complexity of the
part.
• Additive is a natural choice for high-complexity
components because there is complete
geometric freedom to build components with
sophisticated internal structures and features.
• CNC-based subtractive machining is highly
productive for conventionally shaped parts, able
to machine very tight tolerances.
FUSION OF ADDITIVE AND
SUBTRACTIVE MANUFACTURING
• So the more complex the part, the better suited it is
for additive technologies while parts with tighter
tolerance specs need conventional approaches.
• But what about the complex parts with tight
tolerance demands??
• Hybrid is the bridge between those two, where we
can merge the technologies together to print
material, add metal to existing components, grow
parts from nothing, and then be able to machine
them in that same envelope.
 Laser-Assisted Machining
The application of a laser beam as
a secondary process is
advantageous for various primary
processes. The laser beam
strongly influences the processing
zone (e.g., material softening in
cutting, changing electrolyte
conditions in ECM, material
elongation and bending in
Magnetic Field-Assisted Machining
The assistance of a magnetic field in machining is
beneficial for certain processes as it influences their
process physics. In laser-induced plasma machining,
the external magnetic fluid is used to manipulate the
plasma shape for special geometries . In conventional
mechanical machining, application of a magnetic field
helps in directing crack propagation in any direction in
a controlled way.
Electrochemical Discharge Machining
Electrochemical discharge
machining (ECDM) stands for the
combination of electrochemical
and electro-discharge process
energies. According to the
principle of ECDM, the discharge
delay time of the EDM process is
utilized for electrochemical
dissolution which is followed by
V-I characteristics of ECDM
Mechano-Electrochemical Machining
The mechano-electrochemical machining (MECM)
process exploits dual benefits by a combination of
mechanical and electrochemical material removal.
The process is realized by design of a special ECM tool
with a cutting edge. The process is especially useful
for machining hard metals such as Titanium which
suffer from surface activation during ECM process.
The mechanical process facilitates removal of the
activation layer by a cutting edge, thereby enhancing
surface quality and process stability. The process
needs a dedicated tool design and machine tool.
MERITS
Let me take a few examples
• Water jet cutting requires very high water
speeds and laser cutting has micro HAZs. Now
if we combine the two we can get rid of both
the problems
• ECM and EDM both require very high voltages
and can’t machine non-conducting materials,
but a combination of them can, and that too
working at low voltages.
• Similarly use of ultrasonic waves in
electrochemical machining expedites up the
process substantially.
 Abrasive-Waterjet Milling
Abrasive-waterjet machining (AWJM) is widely used in the
cutting of hard and low machinability materials like
titanium alloys, ceramics, metalmatrix composites,
concrete, rocks, etc. The process makes use of the impact
of a water-jet as well as the impact of abrasives for
improving the machinability of certain materials. The main
element of an abrasive-water-jet setup is the
reciprocating pump which is used to pump pure water at
extremely high pressure of 4000-6000 bar.
The abrasive particles are introduced into the water-jet
from a hopper in the mixing chamber. The combined
impact of water-jet and abrasives is useful in cutting or
machining of composites, Kevlar polymer, toughened
Process steps for Hybrid
machining
• SKELETON COMPUTATION- algorithm for
computing the outline of a 3-D polyhedron based
on a classification scheme for points on the
skeleton.

• PART ORIENTATION - determination of the base

face from which the building process of the part
starts. It must provide enough resistance against
the cutting force and must have enough contact
surface area.
PROCESS STEPS
• PART DECOMPOSITION AND BUILDING DIRECTION-
Dividing parts into sub-parts which can be deposited and
machined.

 BUILDING SEQUENCE-

After considering part building order, a directed graph that

represents the precedence relationship among sub-parts
can be constructed. With the precedence graph, a set of
alternative building plans can be generated. Each plan
represents a possible building sequence on the
decomposed geometry and can be chosen optimally
depending upon machine availability or other criteria.
APPLICATIONS
• Coupling additive and subtractive
manufacturing into the same workstation, we
can produce metal parts with very high
precision and accuracy.
Prototyping technology has been the most
interesting advancement for producing CAD
models using hybrid machining processes in the
industry in the past few years.