High-precision forming process based on analysis of selective laser sintering hybrid milling

Selective laser sintering hybrid milling (SHM) is an advanced manufacturing technology that combines the advantages of additive manufacturing and traditional machining. This technology is used to fabricate extremely complicated and high-precision products. The key factor of SHM is the milling process that is performed during the depositing process. However, the thermal shrinkage during the cooling process when depositing new layers on the ones that were machined is a fundamental problem because it creates deformation errors which significantly reduce product accuracy. In this study, the thermal deformation error in SHM was investigated using finite element analysis (FEA) and confirmed experimentally. The mechanism involved in the shrinkage in SHM was studied using three shrinkage rules. Moreover, a compensation technique was proposed with the aim of reducing the thermal deformation error. The results proved that compensation could significantly reduce the deformation error in SHM.