the seminar was on the process of hybrid layer manufacturing in the CNC machines which is well known for subtractive manufacturing

1. PRESENTED BY
Jyothi Prasad B M
USN: 4GM16ME024
Dept. Of Mech. Engg
GMIT
Shrishyla Educational Trust (R), Bheemasamudra
GM INSTITUTE OF TECHNOLOGY, DAVANGERE
DEPARTMENT OF MECHANICAL ENGINEERING
Technical Seminar Presentation On
Retrofitment Of Laser Cladding With CNC
Machine For Hybrid Layer Manufacturing
1
PROJECT GUIDE
Dr. Srinivasa C V
Professor & Head
Dept. Of Mech. Engg
GMIT

2. CONTENT
• Introduction
• Subsystems
• Integration Of Subsystems
• Experimental Setup
• Advantages
• Applications
References
2

3. INTRODUCTION
• Manufacturing is the process of producing final goods with the help of
men, machinery, raw materials, chemicals and tools.
• Additive manufacturing techniques are a group of technologies that
make it possible to produce models and prototypes of any complicated
parts directly from three-dimensional (3D) computer-aided design
(CAD), without using any tools or fixtures.
• The various method of additive manufacturing process are Stereo
Lithography, Liquid Thermal Polymerization, Fused Deposition
Modeling, Ballistic Particle Manufacturing, Binder Jet Printing, Laser
Cladding etc,.
3

4. Laser cladding is a method of depositing
material by which a powdered or wire
feedstock material is melted and consolidated
by use of a laser.
CNC machining is a manufacturing process
in which pre-programmed computer software
dictates the movement of factory tools and
machinery.
4
INTRODUCTION
Fig 1. principle of laser cladding

5. SUBSYSTEMS
5
Fig 2. Subsystems of Laser HLM

6. INTEGRATION OF SUBSYSTEMS
Retrofitment of laser with CNC machine is a challenging task as several
subsystems
• Mechanical Integration Laser head is mechanically mounted on the CNC
spindle. Double acting cylinder with 5/2 solenoid pneumatic valve is
used which provide smooth motion of the laser head.
6
Fig 3(a). Milling Operation Fig 3(b). Laser Cladding Operation

7. • Electrical Integration To make the whole system automatic, extra
relays have been provided for M code. To retract the laser
cladding system, a relay has been used to control the 5/2 solenoid
pneumatic valve of the cylinder. The wire feed and laser beam are
two main parameters to be interface with the CNC machine using
analog bus.
7
INTEGRATION OF SUBSYSTEMS
Fig 4. Sample of M code for linear deposit

8. S. No. M code Command
1 M80 Cladding head down
2 M81 Cladding head up
3 M20 Clamping of the rotary table
4 M21 Release of the rotary table
5 M60 Wire + Laser ready on
6 M61 Wire + Laser ready off
7 M62 Wire on
8 M63 Wire off
9 M64 Laser on
10 M65 Laser off
11 M66 Pilot laser on
12 M67 Pilot laser off
13 M72 Cladding head air on
14 M73 Cladding head air off
15 M74 Inert gas on
16 M75 Inert gas off
8
INTEGRATION OF SUBSYSTEMS
Table 1. List of M codes used

9. In this work, single circular and linear bead has been deposited to
show the initial capability of the retrofitted system. The raw material
used in this study is mild steel wire of diameter 1.2 mm.
9
EXPERIMENTAL SETUP
Fig 5. Real image of deposition

10. 10
EXPERIMENTAL SETUP
Fig 6. Safety shutdown

11. 11
EXPERIMENTAL SETUP
Fig 7. Deposited single bead on both sides of
the substrate
Fig 8. Circular bead Image of the circular deposition (a)
and bead height, width and penetration by tool maker’s
microscopy for A point (b) and for B point (c)

12. • Reduced production time.
• Enhanced thermal control.
• Highly satisfactory repair of parts.
• Production of a functionally graded part.
• Dense coatings with smooth, consistent surface finishes.
• Low dilution and minimal heat affected zone (HAZ)
• Improved material functionality (i.e. corrosion, wear and
oxidation)
12
ADVANTAGES

13. HLM finds several applications in the industries such as
automobile, tooling, and aerospace.
• Repairing turbine components
• Drilling tools
• Agricultural machinery
• Coating of hydraulic cylinders for the mining industry
• Coating for heat exchangers
• High speed cladding in place of hard chromium plating
13
APPLICATION

14. • A unique wire-based laser cladding head has been successfully
retrofitted with an existing 4-axis CNC machine.
• Several subsystems of the laser wire cladding system such as optical
head, power source, wire feeder, air compressor, and inert gas supply
are successfully interfaced with the controller of the CNC machine.
• The integration was carried out in such a way that the retrofitted CNC
machine can efficiently work for additive and subtractive
manufacturing.
• The deposited single beads are found to be smooth and free from any
waviness on the surface.
• In the future, this developed experimental setup will be used for
realizing the objects through hybrid layered manufacturing (HLM)
process.
14
CONCLUSION

15. • Sealy, M.P., Madireddy, G., Williams, R.E., Rao, P., Toursangsaraki, M.: Hybrid
processes in additive manufacturing. J. Manuf. Sci. Eng. 140(6), 060801 (2018)
• Song, Y.A., Park, S.: Experimental investigations into rapid prototyping of
composites by novel hybrid deposition process. J. Mater. Process. Technol.
171(1), 35–40 (2006)
• Xiong, X., Zhang, H., Wang, G.: Metal direct prototyping by using hybrid plasma
deposition and milling. J. Mater. Process. Technol. 209(1), 124–130 (2009)
• Karunakaran, K.P., Suryakumar, S., Pushpa, V., Akula, S.: Retrofitment of a CNC
machine for hybrid layered manufacturing. Int. J. Adv. Manuf. Technol. 45(7–8),
690–703 (2009)
• Kapil, S., Legesse, F., Kulkarni, P., Joshi, P., Desai, A., Karunakaran, K.P.:
Hybrid-layered manufacturing using tungsten inert gas cladding. Prog. Addit.
Manuf. 1(1–2), 79–91 (2016)
• Frazier, W.E.: Metal additive manufacturing: a review. J. Mater. Eng. Perform.
23(6), 1917–1928 (2014)
• Pajukoski, H., Näkki, J., Thieme, S., Tuominen, J., Nowotny, S., Vuoristo, P.:
High performance corrosion resistant coatings by novel coaxial cold-and hot-
wire laser cladding methods. J. Laser Appl. 28(1), 012011 (2016)
• Kapil, S., Legesse, F., Kumar, R., Karunakaran, K.P.: Hybrid layered
manufacturing of turbine blades. Mater. Today Proc. 4(8), 8837–8847 (2017)
15
REFERENCES

16. THANK YOU
16