Additive manufacturing can produce complex parts with poor surface quality, requiring post-processing machining. The combination of additive and machining processes has been identified as a potential solution for achieving sustainable and cleaner production. This approach can enable the use of eco-friendly materials such as recycled or biodegradable ones, while reducing waste, energy consumption, and materials usage. Additionally, it can achieve precision and be used for repairing and finishing complex features. However, there is a lack of literature documenting fundamental material deformation and friction behavior in hybrid additive/subtractive manufacturing, which is necessary for optimizing the process efficiency and achieving cleaner production with reduced material usage and energy. This study investigates material deformation behavior in dry and wet hybrid manufacturing through shear stress, shear angle, and friction. The commonly used Johnson-Cook (JC) model may not adequately represent the deformation behavior in these operations. Therefore, a dual-zone thermomechanical model approach is applied modifying the JC model to hybrid manufacturing. The modified JC constitutive equation and analytical models are used in both modeling and parameter identification. This approach reduces the experimental effort significantly as only a few orthogonal cutting tests are needed to identify the material model and friction. The presented work contributes to a better understanding and modeling of hybrid manufacturing processes, aiming to enhance sustainability by minimizing material waste and energy consumption, ensuring product quality and integrity, and facilitating the adoption of sustainable practices.

增材制造可以生产表面质量较差的复杂零件，需要进行后处理加工。增材和加工工艺的结合已被确定为实现可持续和清洁生产的潜在解决方案。这种方法可以使用环保材料，例如回收材料或可生物降解材料，同时减少浪费、能源消耗和材料使用。此外，它还可以实现精度并用于修复和精加工复杂的特征。然而，缺乏记录混合增材/减材制造中基本材料变形和摩擦行为的文献，而这对于优化工艺效率和通过减少材料使用和能源实现清洁生产是必要的。本研究通过剪切应力、剪切角和摩擦研究干湿混合制造中的材料变形行为。常用的 Johnson-Cook (JC) 模型可能无法充分表示这些操作中的变形行为。因此，将双区热机械模型方法修改为混合制造的 JC 模型。修正的JC本构方程和分析模型用于建模和参数识别。这种方法显着减少了实验工作量，因为只需要进行一些正交切削测试即可确定材料模型和摩擦力。所提出的工作有助于更好地理解和建模混合制造工艺，旨在通过最大限度地减少材料浪费和能源消耗来增强可持续性，