SGER: Design and Manufacturing of Precision Products Directly from CAD by Combined Laser Aided Metal Addition and Subtraction

SGER：通过组合激光辅助金属加减法直接从 CAD 设计和制造精密产品

• 批准号: 0353283
• 负责人: Jyotirmoy Mazumder
• 金额: $ 6.37万
• 依托单位: Regents of the University of Michigan - Ann Arbor
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2003
• 资助国家: 美国
• 起止时间: 2003-11-01 至 2004-10-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0353283&HistoricalAwards=false
• 关键词: SGER; Design; Manufacturing; Precision; Products

SGER ABSTRACT: Design and Manufacturing of Precision Products directly from CAD by combined Laser Aided Metal Addition and SubtractionIn recent years, advanced laser research has created the opportunity to conceptualize a machine tool that can perform sequential laser aided material addition and subtraction on a single platform. The potential economic impact of this technology on the U.S. economy is enormous, as combined laser deposition and removal of metals would greatly reduce the time required to manufacture complex shaped tools and dies. The high potential for Design and Manufacturing of precision products directly from CAD by combined laser aided metal addition and subtraction under the framework of a single system is also associated with high risk. First, there is an urgent need for an integrated CAD/CAE/CAM for laser based fabrication where part/tool performance can be predicted by design engineers using CAE physics based modeling tools in tandem with CAD/CAM to design and fabricate complex precision parts to geometries and surface finish tolerances. CAD-integrated computer aided manufacturing (CAM) systems are not completely developed for either additive or subtractive laser based manufacturing, let alone for the combination of the two. This complexity of design challenge increases substantially when the process is conceptualized for 5 DOF deposition and removal. Second, the deposition process involves two significant challenges: metallurgical and precision size control. The development of precision in-situ measurement technique that can survive in a hot melt metal environment represents another challenge. Third, damage-free laser micromachining for materials removal at the submicron level from a freshly deposited substrate that exhibits considerable residual stress has yet to be explored. Fourth, there is a need to investigate innovative surface modification processes to attain desired surface characteristics. The proposed program will evaluate the critical technologies necessary to rapidly and directly build functional metal parts, tooling, and dies with high precision using a single setup.The broader impact of this SGER will focus on demonstrating the feasibility of a new innovative technology that has the potential to arrest the off shore migration of manufacturing industries. The novel process proposed during the program is expected to replace many steps and complex processes in traditional tooling and die manufacturing, offering the advantage of greatly reducing the time to produce complex tooling and dies with high precision, while simultaneously achieving superior tool life and productivity.

SGER摘要：通过激光辅助金属添加和减去直接从CAD设计和制造精密产品近年来，先进的激光研究创造了机会，概念化的机床，可以在一个平台上执行顺序的激光辅助材料添加和减去。这项技术对美国经济的潜在经济影响是巨大的，因为结合激光沉积和金属去除将大大减少制造复杂形状的工具和模具所需的时间。在单一系统的框架下，通过组合激光辅助金属添加和减少，直接从CAD设计和制造精密产品的高潜力也与高风险相关。首先，迫切需要用于基于激光的制造的集成CAD/CAE/CAM，其中设计工程师可以使用基于CAE物理的建模工具与CAD/CAM协同来预测部件/工具性能，以设计和制造复杂的精密部件以达到几何形状和表面光洁度公差。集成CAD的计算机辅助制造（CAM）系统尚未完全针对基于增材或减材激光制造而开发，更不用说两者的结合了。当工艺被概念化用于5自由度沉积和去除时，设计挑战的复杂性显著增加。其次，沉积过程涉及两个重大挑战：冶金和精确尺寸控制。开发可在热熔金属环境中生存的精密原位测量技术是另一个挑战。第三，无损伤激光微加工的材料去除在亚微米级从一个新沉积的基板，表现出相当大的残余应力还有待探讨。第四，有必要研究创新的表面改性工艺，以获得所需的表面特性。该计划将评估使用单一设置快速直接构建功能性金属零件、工具和高精度模具所需的关键技术。该SGER的更广泛影响将集中在展示一种新的创新技术的可行性上，该技术有可能阻止制造业的离岸海岸迁移。该计划提出的新工艺有望取代传统模具制造中的许多步骤和复杂工艺，其优点是大大缩短了生产高精度复杂模具和模具的时间，同时实现了上级刀具寿命和生产率。