Additive manufacturing is typically a flexible alternative to conventional manufacturing processes. However, manufacturing costs increase due to the effort required to experimentally determine optimum process parameters for customized products or small batches. Therefore, simulation models are needed in order to reduce the amount of effort necessary for experimental testing. For this purpose, a novel technological simulation method for directed energy deposition additive manufacturing is presented here. The Dexel-based simulation allows modeling of additive manufacturing of varying geometric shapes by considering multi-axis machine tool kinematics and local process conditions. The simulation approach can be combined with the simulation of subtractive processes, which enables integrated digital process chains.

Additive and subtractive (Add/Sub) manufacturing processes are increasingly being combined to produce complex parts with unique geometries and properties. However, the design of such combined processes is often challenging as it requires a deep understanding of the interaction between the different processes. On the other hand, digital twin (DT) technology has become a powerful tool in recent years for optimizing manufacturing processes. This article explores the use of the digital twin technology for a holistic process planning of combined additive and subtractive processes. The article describes the integration of laser metal deposition (LMD) and micro-milling prediction models of resulting geometry (width and height), hardness, and surface roughness into the digital twin. This is then used for combined process planning to achieve different target values regarding resulting geometry and surface roughness. For the planning of this combined process chain, further criteria such as tool life, energy, and process time are considered in the optimization, showing the potential for sustainable and efficient production. Sensorless cutting force estimation is also used to detect small cutting forces, with the potential to use this as a soft sensor for roughness estimation. The measured width, height, and roughness as a result of the process parameters suggested by the optimization algorithms showed a mean absolute percentage error (MAPE) of 4, 17, and 16%, respectively.

In modern production, Wire Arc Additive Manufacturing (WAAM) is becoming an essential technology for manufacturing complex components. However, the complexity of planning such processes constrains their widespread use in production cycles. Using various numerical simulation approaches allows for the investigation of resulting geometries with respect to process parameters, reducing the need for experiment-based process planning. Similar to various subtractive processes, there is increased interest in integrating simulation approaches into digital twin applications for planning and optimization of WAAM processes. This requires dynamic geometry mapping and simulation time comparable to the process duration. In this paper, a numerical simulation employing a Dexel-based geometry representation and a model for single-bead geometry parameter prediction is investigated as a vital alternative to Finite Element Method (FEM)-based simulations. The focus lies on the accuracy of the simulated components with respect to the simulation settings, the time needed for it to complete, and the degree of compliance between the simulated and produced multi-layer structures. Using optimized simulation settings achieves an accuracy loss of under 7% due to geometry discretization, with a simulation time that is approximately 37% faster than the process duration. The simulated components closely correspond to the experimental ones in terms of width and height, with a volumetric similarity ranging from 63.3% to 88.8%.

Additive manufacturing has gained interest in the industry due to its flexibility in design and the possibility to integrate functionalities. Thereby, glass has a high potential to be developed also in this field due to its thermal stability, chemical resistance, and optical transmission. Laser glass deposition is a method for fabricating glass components on a glass substrate. The energy input and the resulting temperature are crucial factors in this process, which can influence the material properties and the resulting geometry. Also, depending on the temperature in the substrate, difficulties such as high residual stresses or thermal shock can occur. The temperature on the glass substrate and in the melt zone can be changed either directly by the laser power or laser spot size, or indirectly by other process variables such as travel speed or path planning strategy. In this study, the energy input and the resulting temperature in the melt zone are numerically investigated under selected process parameters. Based on this, a regression function was created so that the generated temperature can be calculated by corresponding laser power, laser spot diameter, and axis velocity. Moreover, different tool path strategies for the production of horizontally multilayered surfaces were thermally investigated. The results showed a more uniform temperature profile with zigzag movement than the spiral tool path. The influence of the turning point angle in path planning on the temperature change was also investigated. It was observed that the 90° corner in contrast to the smaller angle has no significant influence on the temperature change.