Geometric simulation of 5-axis hybrid additive-subtractive manufacturing based on Tri-dexel model

Abstract5-axis hybrid additive-subtractive manufacturing is a new and promising technology for many industrial applications. Because of its complexity, the machining simulation is very important to verify the effectiveness of tool path. However, most simulation methods are proposed for subtractive manufacturing and additive manufacturing separately. This paper presents a novel geometric simulation technique for the 5-axis hybrid additive-subtractive manufacturing, which is based on Laser Engineered Net Shaping (LENS) and milling. In the proposed method, 5-axis additive swept volume elements are represented with Tri-dexel models and then converted into triangular meshes for visualization. Workpiece after additive manufacturing can be then used as a workblank for subtractive manufacturing simulation. Finally, a geometric simulation module is developed based on SIEMENS NX software to demonstrate the feasibility of the proposed simulation method.

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