Pro2AMech: Computer aided product and process parameter design of additively manufac-tured non-assembly mechanisms

增材制造技术（AM）的主要特征在于其极大的设计自由度和与批量大小无关的制造成本，并且另外提供了在单个制造步骤中制造可移动机构的可能性。随后的组装步骤由此变得容易，并且因此导致相当大的成本降低。然而，AF工艺仍然具有缺点，即与传统制造技术相比，可以实现较低的几何精度和公差。这些主要取决于工艺和设备。此外，缺乏可靠和全面的信息，特别是对于FDM制造的非装配机械的设计和生产，以便在工业环境中有效使用。尽管之前的资助阶段通过统计公差分析为增材制造和间隙影响的关节齿轮的运动特性的虚拟验证奠定了基础，仍然缺乏用于后续合成以改进这些机理的综合方法。目前，这是手动完成的，没有进一步的支持系统的支持，从而面临着特别是AM经验不足的产品开发人员与迭代和成本密集型的过程。因此，这是本研究项目的目标，支持产品开发人员没有AM特定的知识，在改进的产品和工艺参数设计的增材制造，非装配机构的综合支持系统。除了通过考虑与工艺相关的对机制运行行为的影响来扩展和调整第一资助阶段产生的可用统计公差分析外，主要重点是开发用于改进产品和工艺参数设计的方法。为此，开发了用于在增材制造设计方面改进标称产品设计的方法，并在商业CAD系统中实施。为了改进工艺参数设计，现有的方法如e。G.自适应切片和非平面打印用于优化不同目标，如几何精度，可实现的公差和构建时间，在预处理范围内得到改进，并在此基础上开发新方法。最后，开发的方法将在一个支持系统的帮助下，一个共同的，跨学科的软件演示和验证，其适用性将在用户研究进行评估。因此，产品开发人员可以在产品和工艺参数的设计、功能分析以及随后的增材非装配机构的生产中以广泛的自动化方式得到支持，以便最终实现其在工业环境中的应用。

Additive manufacturing techniques (AM) are mainly characterized by their great freedom of design and batch size independent manufacturing costs and additionally offer the possibility to manufac-ture movable mechanisms in a single manufacturing step. A subsequent assembly step becomes thereby dispensable and thus leads to a considerable cost reduction. However, AF processes still have the disadvantage that lower geometric accuracies and tolerances can be achieved com-pared to conventional manufacturing technologies. These are mostly process- and equipment dependent. Additionally, reliable and comprehensive information is missing especially for the de-sign and production of FDM-manufactured, non-assembly mechanics to be used effectively in an industrial context.Although the previous funding phase created a basis for the virtual validation of the motion be-havior of additively manufactured and clearance-affected joint gears by means of statistical toler-ance analysis, there is still a lack of a comprehensive method for a subsequent synthesis to im-prove these mechanisms. At present, this is done manually and without further support by a sup-port system, thus confronting especially AM-inexperienced product developers with an iterative and cost-intensive process.Therefore, it is the goal of this research project to support product developers without AM-specific knowledge in improving the product and process parameter design of additively manufactured, non-assembly mechanisms by a comprehensive support system. In addition to the extension and adaptation of the available statistical tolerance analysis resulting from the first funding phase by considering process-related influences on the operating behaviour of the mechanisms, the devel-opment of methods for the improvement of the product and process parameter design is the main focus. For this purpose, methods for improving the nominal product design in terms of the Design for Additive Manufacturing are developed and implemented in commercial CAD systems. For the improvement of the process parameter design, existing approaches like e. g. Adaptive Slicing and Non-planar Printing for the optimization of different objectives such as geometric accuracy, achievable tolerances and build time are improved within the scope of pre-processing and new methods are developed on this basis. Finally, the developed methods will be linked in a support system with the help of a common, interdisciplinary software demonstrator and validated and their applicability will be evaluated in user studies. Thus, product developers can be supported in a widely automated way in the design of the product and process parameters, the functional analy-sis and the subsequent production of additive, non-assembly mechanisms, in order to finally ena-ble its application in the industrial context.