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

SGER摘要：激光辅助金属加减法直接从CAD设计和制造精密产品近年来，先进的激光研究创造了将能够在单一平台上执行连续激光辅助材料加减法的机床概念化的机会。这项技术对美国经济的潜在经济影响是巨大的，因为激光沉积和去除金属相结合将大大减少制造复杂形状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加法和减法直接从CAD设计和制造精密产品的高潜力也与高风险相关。首先，迫切需要一种用于激光加工的集成化CAD/CAE/CAM，设计工程师可以使用基于CAE物理的建模工具与CAD/CAM相结合来预测零件/刀具性能，以设计和制造符合几何尺寸和表面光洁度的复杂精密零件。CAD集成的计算机辅助制造(CAM)系统并不是完全为基于加法或减法激光的制造开发的，更不用说为两者的组合开发了。当五自由度沉积和去除过程概念化时，这种设计挑战的复杂性大大增加。其次，沉积过程涉及两个重大挑战：冶金和精密尺寸控制。能够在热熔化金属环境中生存的精密原位测量技术的发展是另一个挑战。第三，无损伤激光微加工用于从新沉积的具有相当大残余应力的衬底上去除亚微米级的材料还有待探索。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。拟议的计划将评估使用单一设备快速、直接、高精度地制造功能金属部件、工装和模具所需的关键技术。这项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，该技术有可能阻止制造业的离岸迁移。在该计划中提出的新工艺有望取代传统工模制造中的许多步骤和复杂工艺，提供极大地减少生产高精度复杂工模和模具的时间，同时实现卓越的刀具寿命和生产率。

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.