Élaboration de gammes de fabrication pour l'hybridation des procédés DED-fil et usinage 5 axes

The production of complex multi-feature parts using hybrid DED and machining processes requires the development of specific process planning strategies that account for the characteristics of each process and their interactions. To enable such planning, DED manufacturing features — which are not yet defined in international standards and are rarely addressed in the literature — are first formally defined. This definition, structured around various additive manufacturing processes, incorporates an estimation of each feature's thermal behavior based on geometric indicators available during the design phase. These indicators allow features to be classified by their thermal behavior (conduction, convection, and heat accumulation), providing a first tool for assessing the thermal behavior of multi-feature parts. Based on definitions for both machining and DED features, feasible manufacturing sequences are computed while considering all relevant constraints related to feature interactions (e.g., contact, overhangs). To integrate thermal behavior into process planning, a dedicated model is used to simulate a large number of production sequences efficiently. This model calculates heat fluxes between features and the ambient environment to generate thermal indicators representative of each feature's overall temperature. All generated sequences can then be ranked based on these thermal indicators, enabling informed selection of the most thermally suitable process plan for the given part.