Surface Integrity in Hybrid Machining Processes

Hybrid manufacturing processes are based on the simultaneous and controlled interaction of process mechanisms and/or energy sources/tools having a significant effect on the process performance. There are various examples such as laser assisted cutting, vibration assisted grinding and grind-hardening. Hybrid processes have a large influence on the machining characteristics resulting in a higher machineability, reductions of process forces and tool wear, etc. Due to the combined action of processes, it also has an important positive or sometimes negative effect on the surface integrity of machined parts. This key-note/overview paper gives first a definition and classification of hybrid processes. It is then followed by a description of the principles and applications of some common hybrid processes, highlighting the effects on the surface and sub-surface quality. The paper is largely based on the results of an on-going working group within the International Academy for Production Engineering (CIRP).