Theoretical modelling and prediction of surface roughness for hybrid additive–subtractive manufacturing processes
针对混合增材-减材制造过程，建立了表面粗糙度的解析模型，并提出新的表面轮廓表示方法以提高预测精度，实验验证了模型的有效性。
Hybrid additive–subtractive manufacturing processes are becoming increasingly popular as a promising solution to overcome the current limitations of Additive Manufacturing (AM) technology and improve the dimensional accuracy and surface quality of parts. Surface roughness, as one of the most important surface quality measures, plays a key role in the fit of assemblies and thus needs to be thoroughly evaluated at the design and manufacturing stages. However, most of the studies on surface roughness modelling and analysis employ empirical approaches, and only consider the effect of a single manufacturing process. In particular, the existing surface roughness models are not applicable to hybrid additive–subtractive manufacturing processes in which a secondary process is involved. In this article, analytical models are established to predict the surface roughness of parts fabricated by AM as well as hybrid additive–subtractive manufacturing processes. A novel surface profile representation scheme is also proposed to increase the prediction accuracy. Case studies are performed to validate the effectiveness of the proposed models. An average of 4.25% error is observed for the AM case, which is significantly smaller than the prediction error of the existing models in the literature. Furthermore, in the hybrid case, an average of 91.83% accuracy is obtained.