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KYOCERA SGS Precision Tools Group
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Manufacturing in the modern age is overshadowed by an ongoing debate between two distinct but interwoven forces – CNC Subtractive Manufacturing (CSM) and Additive Manufacturing (AM). This article delves into an analysis of these two approaches, highlighting their respective strengths, and weaknesses, and exploring the burgeoning field of Additive-Subtractive Hybrid Manufacturing (ASHM). Additionally, we will discuss the pivotal role of carbide tooling and its continued relevance in this era.
Before we delve into the intricacies of CNC Subtractive Manufacturing (CSM) and Additive Manufacturing (AM), it’s helpful to understand the “buy-to-fly” ratio. This ratio signifies the mass of the initial raw material billet in comparison to the final finished part mass. In CSM, the “buy-to-fly” ratio is often high, indicating that a significant portion of the initial material is removed during machining. Not only does this result in substantial material waste, but it escalates costs and environmental concerns. The “buy-to-fly” ratio is a relevant concern in industries like aerospace where its complex parts start as massive billets and much of the material is removed to reach the desired specifications [1].
CSM, a tried-and-true method, boasts several strengths:
Nonetheless, subtractive manufacturing has its limitations:
Additive Manufacturing (AM), often referred to as 3D printing, has witnessed a surge in popularity for various reasons:
Additive Manufacturing, in general, offers a range of advantages:
Additive-Subtractive Hybrid Manufacturing (ASHM) represents the amalgamation of the strengths of both AM and CSM within a single workstation. The combination of AM and CSM within a single workstation allows the production of complex parts with internal components requiring the finish quality of CSM. Traditionally, CSM would be incapable of reaching these internal components. ASHM offers many advantages including the following [1,2]:
Operating an Additive-Subtractive Hybrid Manufacturing (ASHM) system is a complex endeavor, and energy consumption is one of its foremost challenges. While ASHM, like Additive Manufacturing (AM), excels in material efficiency, it’s crucial to note that ASHM’s energy demands surpass even those of AM. This heightened energy consumption within ASHM can be attributed to the amalgamation of multiple energy-intensive devices, including laser machines, chillers, powder feeders, and hybrid machine tools, all operating concurrently and collectively contributing to substantial energy consumption. Nonetheless, ASHM remains a promising technology, especially if the energy problem is effectively addressed [1].
In the realm of modern manufacturing, CNC Subtractive Manufacturing (CSM) stands as the bedrock of precision, versatility, and top-notch surface quality. Conversely, Additive Manufacturing (AM) represents an exciting frontier for intricate designs, yet it faces limitations in industries that demand speed of manufacture, precision, material variety, and impeccable surface finish.
In this dynamic manufacturing landscape, Additive-Subtractive Hybrid Manufacturing (ASHM) emerges as a promising synthesis of these strengths. While AM continues to make waves, traditional Subtractive Manufacturing and the enduring relevance of carbide tooling remain indispensable.
To excel in your machining endeavors, explore SGS’s extensive range of solid carbide tooling, featuring tools varying from general-purpose to meticulously engineered high-performance end mills with specialized coatings. Talk to your regional SGS Sales Engineer today and find a solution that will drive your production forward.
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Machinists require reliable solutions to tackle intricate tasks efficiently. Indexable tooling provides exceptional flexibility, quality, durability, and delivers high-performance results. Customize your tooling for specific tasks by choosing the ideal combination of inserts and holders to optimize performance.
Explore our SGS branded high-performance and versatile solid round tooling options. Our quality tooling not only ensures precision but also minimizes downtime, allowing for increased material removal per hour. Explore a range of options including end mills, drills, routers, countersinks, and more to find the perfect tools for your specific needs.
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KYOCERA SGS Precision Tools, Inc.
(330) 686-5700
150 Marc Drive
Cuyahoga Falls, OH 44223
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