Abstract
Additive manufacturing technology overcomes the limitations imposed by traditional manufacturing techniques, such as fixtures, tools, and molds, thereby enabling a high degree of design freedom for parts and attracting significant attention. Combined with subtractive manufacturing technology, additive and subtractive hybrid manufacturing (ASHM) has the potential to enhance surface quality and machining accuracy. This paper proposes a method for simulating the additive and subtractive manufacturing process, enabling accurate deformation prediction during processing. The relationship between stress distribution and thermal stress deformation of thin-walled 316L stainless steel parts prepared by Laser Metal Deposition (LMD) was investigated using linear scanning with a laser displacement sensor and finite element simulation. The changes in stress and deformation of these thin-walled parts after milling were also examined. Firstly, 316L stainless steel box-shaped thin-walled parts were fabricated using additive manufacturing, and the profile information was measured using a Micro Laser Displacement Sensor. Then, finite element software was employed to simulate the stress and deformation of the box-shaped thin-walled part during the additive manufacturing process. The experiments mentioned were conducted to validate the finite element model. Finally, based on the simulation of the box-shaped part, a simulation prediction was made for the box-shaped thin-walled parts produced by two-stage additive and subtractive manufacturing. The results show that the deformation tendency of outward twisting and expanding occurs in the additive process to the box-shaped thin-walled part, and the deformation increases gradually with the increase of the height. Meanwhile, the milling process is significant for improving the surface quality and dimensional accuracy of the additive parts. The research process and results of the thesis have laid the foundation for further research on the influence of subtractive process parameters on the surface quality of 316L stainless steel additive parts and subsequent additive and subtractive hybrid manufacturing of complex parts.