hybrid machining process

1.     Introduction

Hybrid machining is combine different machining processes to manufacture components with a better machining performance. The objective of hybridizing processes is the positive effect of the hybrid process is more than double advantages of the single processes [12]. Hybrid processes developing due to the advent of novel materials with extreme properties, requirements of enhanced machining precision and complex shaped parts which earlier difficult or not possible to machine with existing conventional and non-conventional machining technologies. The term “hybrid process” in machining is related to the combination of different process energies or assisting a specific process by using another process energy.

A hybrid process can be used in different terms:

1. Combination of different active energy sources which act at the same time in the processing zone (laserelectrochemical machining).

2. Processes which combine process steps that are usually performed in two or more process steps (grindhardening).

3. Hybrid machines, integrating different processes within one machining platform (sequential milling and electric discharge machining).

Classification of hybrid machining processes

Fig.1 shows the broad classification of hybrid machining processes. In assisted hybrid machining, one process energy assists the main process energy which is responsible for material removal. For instance, in laser-assisted turning a laser facilitates material removal by cutting tool. In combined hybrid processes, the process energies react simultaneously with the workpiece and participate in material removal. For example, in mechano-electrochemical machining the material removal takes place by both cutting action and anodic dissolution. Other hybrid processing techniques include controlled application of process mechanism with the objective to reduce the process chain or to combine two different processes on the same machine platform. For example, in grind hardening the two-step processes of grinding and heat treatment are combined at one machine platform by utilizing the heat treatment are combined at one machine platform by utilizing the heat generated in the grinding operation for hardening of the work piece.