About this Abstract |
| Meeting |
MS&T25: Materials Science & Technology
|
| Symposium
|
Additive Manufacturing: Design, Materials, Manufacturing, Challenges and Applications
|
| Presentation Title |
Hybrid Multi-Axis Additive and Subtractive Manufacturing: Toolpath Design and Simulation for Thermal and Geometric Control |
| Author(s) |
Yousub Lee, Miguel Hoffmann Rodriguez , Xinyi Xiao, Thomas Feldhausen |
| On-Site Speaker (Planned) |
Yousub Lee |
| Abstract Scope |
While 3-axis metal additive manufacturing (AM) is well-studied, 5-axis AM remains underdeveloped, especially in simulation and hybrid additive and subtractive integration despite its advantages in geometry complexity, material efficiency, and productivity. This presentation introduces interactive 5-axis slicing and toolpath strategies designed to control part distortion and mechanical properties through integration with the finite element method. Three tool path strategies, 1) 3-axis, 2) 5-axis, and 3) 3+2 axis, are evaluated in terms of distortion and mechanical performance. A tapered L-shaped wall printed using a 3-axis strategy showed a 50° underbuilt angle due to overheating at overhangs. In contrast, the 5-axis method achieved a precise 60° overhang due to increased deposition distance. Finally, we explore thermo-mechanical simulation integrated with 5-axis toolpath strategies using thermal sensor data to analyze temperature distribution and optimize part distortion and residual stress demonstrating both the potential and challenges of this approach. |