As a part of the worldwide analysis challenge Advert-Proc-Add II (Superior Processing of Additively Manufactured Components II), the Institute of Manufacturing Engineering and Photonic Applied sciences (IFT) at TU Wien has developed revolutionary approaches for combining additive and subtractive strategies alongside all the course of chain.
The Institute of Manufacturing Engineering and Photonic Applied sciences (IFT) on the Vienna College of Know-how (TU Wien) is considered one of Europe’s main analysis establishments within the subject of producing science. With a give attention to additive manufacturing (AM), precision machining, and digital course of integration, IFT goals to develop revolutionary options for the manufacturing of the longer term.
The Advert-Proc-Add II challenge—funded by the Austrian Analysis Promotion Company (FFG), the German Federal Ministry for Financial Affairs and Local weather Motion (BMWK), and the Flanders Company for Innovation & Entrepreneurship (VLAIO)—was coordinated by the ecoplus Mechatronics Cluster, FKM, and KU Leuven. Its purpose was to reinforce the cost-efficiency and precision of producing extremely complicated elements. On this context, IFT performed a key function in growing revolutionary, application-ready technological options utilizing simulation-based course of fashions, that are anticipated to make future industrial purposes considerably extra environment friendly and sustainable.
One in all IFT’s analysis priorities was analyzing the ensuing materials construction and floor integrity alongside the Additive-Subtractive Manufacturing (ASM) course of chain. Within the space of Wire-Arc Additive Manufacturing (WAAM), researchers in Vienna examined, amongst different components, the affect of varied course of parameters and post-processing strategies on floor and substructure properties. The findings present essential insights for the focused adjustment of part traits reminiscent of hardness, residual stresses, and floor roughness.
Machine Hammer Peening, an intermediate therapy methodology examined by IFT, demonstrated vital enhancements within the densification and homogenization of the surfaces of additively manufactured elements. When mixed with strategies reminiscent of shot peening and Hirtisation, post-processing might be systematically optimized.
A key contribution from IFT was growing a simulation mannequin to foretell the topography, stress distribution, and deformation of additively manufactured elements even earlier than the manufacturing course of begins. Utilizing the Finite Ingredient Methodology (FEM), a basis was established for predictive course of planning.
Additional, the simulation was prolonged to incorporate an evaluation of machinability to optimize machining methods prematurely based mostly on the AM information. This allows exact definition of the minimal obligatory machining allowances, considerably decreasing materials consumption and post-processing time.
To help the digital integration of the ASM course of chain, IFT additionally developed a prototype of a CAM rule engine. This allows the automated adjustment of toolpaths based mostly on sensor-driven course of information. The system was embedded right into a custom-developed cross-process database that hyperlinks parameters and sensor information from varied manufacturing levels. This brings the imaginative and prescient of a completely data-driven course of chain inside attain.
IFT emphasised industrial applicability, particularly for small and medium-sized enterprises (SMEs). By strategically combining analysis, simulation, and sensible validation, usable options had been developed in collaboration with 15 Austrian business companions, together with approaches for seamlessly integrating WAAM processes into current manufacturing strains—the result’s sensible, cost-effective, and scalable applied sciences.
The Advert-Proc-Add II challenge was coordinated by the Analysis Affiliation for Mechanical Engineering e.V. (FKM) and supported by famend establishments such because the Institute for Machine Instruments (IfW) on the College of Stuttgart and the Institute for Machining Know-how (ISF) at TU Dortmund College. IFT, with its interdisciplinary crew led by Univ.-Prof. Dipl.-Ing. Dr.techn. habil. Friedrich Bleicher performed a central function within the challenge.
The analysis findings are shared by means of skilled occasions, commerce gala’s, and publications, together with at EMO 2025 in Hanover and main worldwide journals. The ultimate report may be requested by contacting FKM | Forschungskuratorium Maschinenbau eV at [email protected].
