An Energy Consumption Modeling Method for DED-based Hybrid Additive Manufacturing

The awareness of energy consumption is gaining much more attention in manufacturing due to its economic and sustainability benefits. An energy consumption model is needed for quantifying the consumption and predicting the impact of various process parameters in manufacturing. This paper aims to develop an energy consumption model based on Specific Energy Consumption (SEC) for Direct Energy Deposition (DED) based Hybrid Additive Manufacturing (HAM). Three significant factors, including scanning speed, laser power, feed rate, and their interactions, are analyzed to investigate their effect on energy consumption. The results suggest that all the factors have a strong influence, but their interaction effects have a weak influence on the energy consumption for HAM. Among the three process parameters, laser power has the most significant effect on energy consumption. Based on the regression analysis result, this study recommends high scanning speed while the laser power and feed rate should be low to reduce energy consumption. Also, the idle time has significant energy consumption during the whole HAM process.