The hybrid manufacturing process which integrates additive manufacturing with subtractive machining is competitive and promising in component repair. To automate this process, detecting the missing volume and generating the deposition tracks is the key. In this study, strategies for repairing defects on flat and non-flat surfaces were investigated. A cost-effective reverse engineering tool was utilized to reconstruct STL models of damaged objects. Point data of the fracture surface on flat surfaces was obtained to generate the tool path for material building up. For defects on non-flat surfaces, the damaged model was best-fitted with the nominal model. Then both models were sliced and by using area comparison method, the defective domain was detected. Then a series of projection rays were utilized to slice the damaged cross-sections to extract the repair volume. Finally, repair experiments were performed to assess the repair quality through repair automation.
X. Zhang et al., "Metallic Components Repair Strategies using the Hybrid Manufacturing Process," Proceedings of the 28th Annual International Solid Freeform Fabrication Symposium (2017, Austin, TX), pp. 1862 - 1876, University of Texas at Austin, Aug 2017.
28th Annual International Solid Freeform Fabrication Symposium -- An Additive Manufacturing Conference, SFF 2017 (2017: Aug. 7-9, Austin, TX)
Mechanical and Aerospace Engineering
Intelligent Systems Center
Keywords and Phrases
Hybrid Manufacturing; Defect Repair; Laser Metal Deposition; Reverse Engineering
Article - Conference proceedings
09 Aug 2017
This project was supported by National Science Foundation Grants CMMI-1547042 and CMMI 1625736, and the Intelligent Systems Center, Center for Aerospace Manufacturing Technologies, and Material Research Center at Missouri S&T. Their financial support is greatly appreciated.