Hybrid manufacturing study based on five-axis linkage and LENS

In order to make up for the limitations of manufacturing technology, laser engineered near shaping (LENS) device was integrated on a five-axis linkage computerized numerical control (CNC) machine by applying the technology of adding and subtracting materials, which forms an equipment realizing additive and subtractive machining structurally; UG post-processing builder was used to develop a post-processing machining system of additive and subtractive materials, which realizes parts' hybrid manufacturing functionally. The results show that hybrid manufacturing can achieve one-time forming for complex metal parts, and reduce machining errors and inefficiencies caused by multiple clamping. Compared with additive or subtractive processing mode, the product yield rate is increased more than 20%, processing time is shortened more than 45%, supporting amount is reduced more than 30%, respectively. Especially for parts with a structure of closed internal flow channel, the surface accuracy of the internal flow channel can reach 0.6μm by using hybrid manufacturing method, which effectively extends parts' service life. Hybrid manufacturing technology can realize processing with weak support, no support, no interference, high-precision and high-efficiency. This research provides reference for the process plan, manufacturing mode, and application expansion of laser hybrid manufacturing.