Machining behavior of Inconel 718 in hybrid additive and subtractive manufacturing

Additive manufacturing can produce complex parts with poor surface quality, requiring post-processing machining. The combination of additive and machining processes has been identified as a potential solution for achieving sustainable and cleaner production. This approach can enable the use of eco-friendly materials such as recycled or biodegradable ones, while reducing waste, energy consumption, and materials usage. Additionally, it can achieve precision and be used for repairing and finishing complex features. However, there is a lack of literature documenting fundamental material deformation and friction behavior in hybrid additive/subtractive manufacturing, which is necessary for optimizing the process efficiency and achieving cleaner production with reduced material usage and energy. This study investigates material deformation behavior in dry and wet hybrid manufacturing through shear stress, shear angle, and friction. The commonly used Johnson-Cook (JC) model may not adequately represent the deformation behavior in these operations. Therefore, a dual-zone thermomechanical model approach is applied modifying the JC model to hybrid manufacturing. The modified JC constitutive equation and analytical models are used in both modeling and parameter identification. This approach reduces the experimental effort significantly as only a few orthogonal cutting tests are needed to identify the material model and friction. The presented work contributes to a better understanding and modeling of hybrid manufacturing processes, aiming to enhance sustainability by minimizing material waste and energy consumption, ensuring product quality and integrity, and facilitating the adoption of sustainable practices.