Process combination of single point incremental forming and laser powder deposition for the manufacturing of lightweight components

用于制造轻质部件的单点渐进成形和激光粉末沉积工艺组合

• 批准号: 385276922
• 负责人: Professor Dr.-Ing. A. Erman Tekkaya
• 金额: --
• 依托单位: Institut für Umformtechnik und Leichtbau (IUL)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2017
• 资助国家: 德国
• 起止时间: 2016-12-31 至 2021-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/385276922?language=en
• 关键词: Process; combination; single; point; incremental

The existing approaches for the manufacturing of components either by means of forming methods or additive manufacturing technologies result in considerable disadvantages each. By an innovative combination of the two processes single point incremental forming and additive manufacturing in one machine, the advantages of both manufacturing worlds are merged for the production of lightweight components with a high integration of functions. Among the forming methods, the single point incremental forming offers the opportunity to cover a large range of components in small batch sizes without using product-specific dies. The components have a shell-like character and serve principally for covering large areas, e.g. functioning as structural components. Via additive manufacturing by laser powder deposition geometrical features can be added individually and locally, making an optimized functional adapted lightweight design of components with a high quality lightweight design possible, again without using product-specific dies. The technological basis for the development and fundamental research of the novel process combination is a new machine for the combined additive and subtractive manufacturing in a 5-axis machining center, funded by the DFG. Beginning with the development of the die technology for the integration of the forming operations into the machine, the additive deposition with the powder nozzle on the plane and curved surfaces afflicted with grooves, resulting from the single point incremental forming process, shall be investigated. The hybrid parts will be tested mechanically and investigated microstructurally with samples and test devices which have to be developed. The single point incremental forming shall be conditioned in such a way that, in terms of the manufacturing and the properties, an optimized substrate base is created, which allows the best possible bond for the additive deposit. In the field of additive manufacturing it should be examined how the powder nozzle path strategy must be adapted globally (operating distance of the powder nozzle to the substrate) or also locally (in the dimension of the groove depth). As a result, the fundamentals and the technological limits for this novel process combination and product group shall be explored and the potential, in regard to an energy and resource efficient manufacturing, shall be evaluated.

用于通过成形方法或增材制造技术制造部件的现有方法各自导致相当大的缺点。通过将单点渐进成形和增材制造这两种工艺创新地结合在一台机器上，将两种制造领域的优势融合在一起，用于生产具有高度集成功能的轻质部件。在成形方法中，单点渐进成形提供了在不使用产品特定模具的情况下以小批量尺寸覆盖大范围部件的机会。所述部件具有壳状特征并且主要用于覆盖大面积，例如用作结构部件。通过激光粉末沉积的增材制造，可以单独和局部地添加几何特征，从而使具有高质量轻量化设计的组件的优化功能适应轻量化设计成为可能，同样无需使用产品特定的模具。新工艺组合的开发和基础研究的技术基础是DFG资助的5轴加工中心中组合增材和减材制造的新机器。从模具技术的开发开始，将成型操作集成到机器中，应研究由单点渐进成型工艺产生的带有凹槽的平面和曲面上的粉末喷嘴的添加剂沉积。将对混合部件进行机械测试，并使用必须开发的样品和测试装置进行微观结构研究。单点渐进成型应根据制造和性能进行调整，以创建优化的基底，从而为添加剂存款提供最佳的粘合。在增材制造领域中，应检查粉末喷嘴路径策略必须如何全局地（粉末喷嘴到基底的操作距离）或局部地（在凹槽深度的维度上）适配。因此，应探索这种新型工艺组合和产品组的基本原理和技术限制，并评估其在能源和资源高效制造方面的潜力。