Hybrid Manufacturing

Traditionally manufacturing process would be either additive manufacturing or subtractive machining.

Both these methodologies have its advantages and disadvantages. The major factor concerning AM
and SM is the material required and surface finish.

SM/CNC AM

• Repeatability • Less material

• Precise wastage
• Surface Finish • Geometrical
• High Productivity freedom
• Material Wastage • Material options
• Long cycle-time
• Poor surface finish

Hybrid manufacturing combines the advantages of AM and SM. It allows for building up and repairing
damaged parts only when needed, which decreases the additional finishing work required. As AM
helps in using different materials layer by layer it is possible to impart t=different mechanical/thermal
properties to it. Since the same equipment helps in AM and SM the lead time and work handling Can
be reduced significantly.

The first issue with using hybrid manufacturing is the high initial investment and implementation cost
associated with the equipment. Another issue is the unavailability of such a machine for mass
production in a timely manner. One should have a better understanding of the best sequence of
operation (additive and subtractive) so as to reduce the material addition. A separate tool collision
detection system to identify the proximity of tool with respect to the newly added material.

It is well-positioned for prototyping, repair and small or single-part production. Industries which
benefits the most are aerospace, defence, medical and mould and die. It can efficiently produce or
perform complicated mould repairs and add materials for extra durability. In short it is a developing
manufacturing technology, which finds a major application in near future.

INTRODUCTION TO FMS

A flexible manufacturing system (FMS) is an arrangement of machines, interconnected by a transport

system. The transporter carries work to the machines on pallets or other interface units so that work-
machine registration is accurate, rapid and automatic. A central computer controls both machines and
transport system. Or an FMS consists of a group of processing work stations interconnected by means
of an automated material handling and storage system and controlled by integrated computer control
system. FMS is called flexible due to the reason that it is capable of processing a variety of different
part styles simultaneously at the workstation and quantities of production can be adjusted in response
to changing demand patterns.

BASIC COMPONENTS OF FMS: The basic components of FMS are:

1. Workstations

2. Automated Material Handling and Storage system.

3. Computer Control System

1. Workstations: In present day application these workstations are typically computer numerical
control (CNC) machine tools that perform machining operation on families of parts. Flexible
manufacturing systems are being designed with other type of processing equipment‘s including
inspection stations, assembly works and sheet metal presses. The various workstations are

1. Machining centers

2. Load and unload stations

3. Assembly work stations

4. Inspection stations

5. Forging stations

6. Sheet metal processing, etc.

2. Automated Material Handling and Storage system: The various automated material handling
systems are used to transport work parts and subassembly parts between the processing stations,
sometimes incorporating storage into function. The various functions of automated material handling
and storage system are

1. Random and independent movement of work parts between workstations

2. Handling of a variety of work part configurations

3. Temporary storage

4. Convenient access for loading and unloading of work parts

5. Compatible with computer control.

3. Computer Control System: It is used to coordinate the activities of the processing stations and the
material handling system in the FMS. The various functions of computer control system are:

(i) Control of each work station

(ii) Distribution of control instruction to work station

(iii) Production control

(vi) Traffic control

(v) Shuttle control

(vi) Work handling system and monitoring

(vii) System performance monitoring and reporting

DIFFERENT TYPES OF FMS

The different types of FMS are

1. Sequential FMS

2. Random FMS

3. Dedicated FMS

4. Engineered FMS

5. Modular FMS

Sequential FMS: It manufactures one-piece part batch type and then planning and preparation is
carried out for the next piece part batch type to be manufactured. It operates like a small batch flexible
transfer line.

Random FMS: It manufactures any random mix of piece part types at any one time.

Dedicated FMS: It continually manufactures, for extended periods, the same but limited mix of piece
part batch types.

Engineered FMS: It manufactures the same mix its lifetime.

Modular FMS: modular FMS with a sophisticated FMS host, enables and FMS user to expand their
FMS capabilities in a stepwise fashion into any of the previous four types of FMS. modular FMS, with
a sophisticated FMS host, enables and FMS

Types of FMS Layout :

The different types of FMS layouts are :

1. Progressive or Line Type

2. Loop Type
3. Ladder Type
4. Open field type
5. Robot centred type
1.Progressive or Line type

: The machines and handling system are arranged in a line in this type of system. It is
most appropriate for a system in which the part progress from one workstation to the
next in a well-defined sequence with no back flow. The operation of this type of system
is very similar to transfer type. Work always flows in unidirectional path as shown in the
figure below.

2.Loop Type :The basic loop configuration is as shown in figure below. The parts
usually move in one direction around the loop, with the capability to stop and be
transferred to any station. The loading and unloading station are typically located at
one end of the loop as shown in the figure below.
3.Ladder Type:The configuration is as shown in the figure below. The loading and
unloading station is typically located at the same end. The sequence to the
operation/transfer of parts from one machine tool to another is in the form of ladder
steps as shown in the figure below.
4. Open Field Type :The configuration of the open field is as shown in the figure. The
loading and unloading station is typically located at the same end. The parts will go
through all the substations, such as CNC machines, coordinate measuring machines
and wash station by thehelp of AGV’sfrom one substation to another.
6.Robot Centered Type : Robot centered cell is a relatively new form of flexible system
in which one or more robots are used as the material handling systems as shown in
the figure below. Industrial robots can be equipped with grippers that make them well
suited for handling of rotational parts.