Due to increasing interest in additive manufacturing processes for metal components,
there are several needs on research and development regarding the additive-subtractive
manufacturing (ASM) process chain. As in all technological areas, the interest in these
processes is also increasing the requirements in terms of quality. For additive
manufacturing, this means increased requirements for surface quality as well as
dimensions, shape, and position tolerances. Furthermore, AM and the entire ASM process
chain must be economically competitive.
The Ad-Proc-Add II project engages these challenges by investigating the ASM process
chain from start to finish. The additive pre-processing will be improved for optimal
subsequent subtractive process steps regarding economic factors such as minimal
allowances, reduced process forces, optimized support structures, and tool wear.
Tweaking of AM parameters will quantify and reveal optimization potential for surface
integrity and enable better control. Moreover, different interrelations between ASM
process steps will be investigated to enable a hybrid and flexible combination of different
AM processes (DED and LPBF) and pre-machined workpieces. A holistic view of the ASM
chain will be created with the help of numeric additive and subtractive process simulation
and data processing so that pre-defined workpiece properties can be achieved directly
while providing a minimum of uncertainty. Additionally, to enable advanced optimization
potential such as improved toolpath strategies (CAD-CAM optimization) and increased
process automation capabilities, an ASM process chain knowledge database prototype,
combining multi-sensor data inputs from different process steps, will be developed.
The Ad‐Proc‐Add II project is expected to have a significant impact on industries such as
tool making, machinery and manufacturing in the participating countries, which possess a
significant relevance. The project will provide fundamental insights, detailed
understanding and the technological background for a knowledge based and effective
implementation of innovative AM techniques in various applications. New and improved
products based on the results of this project can be developed by the respective industries
to accelerate the adoption and growth of AM.
The findings, insights, prototypes, and experimental results will be presented towards the
international public by workshops, practical seminars, publications, website, and exhibition
at fairs. The project will be accompanied by a user committee of SMEs from all relevant
market sectors: tool manufacturing, additive manufacturing equipment, machine tool
manufactures, software and service providers, as well as end-users. The intensive
communication with the industrial partners ensures the elaboration of industrially relevant
and usable results.