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

现有的制造部件的方法，无论是通过成形方法还是增材制造技术，都有相当大的缺点。通过将单点增量成形和增材制造两种工艺在一台机器上的创新结合，将两种制造世界的优势融合在一起，生产出具有高度集成功能的轻质部件。在成形方法中，单点增量成形提供了在不使用产品特定模具的情况下以小批量覆盖大范围部件的机会。这些组件具有壳状特征，主要用于覆盖大面积，例如作为结构组件。通过激光粉末沉积的增材制造，可以单独和局部添加几何特征，使组件的优化功能适应轻量化设计，具有高质量的轻量化设计成为可能，而无需使用特定产品的模具。新工艺组合的开发和基础研究的技术基础是DFG资助的一种用于五轴加工中心加减法组合制造的新机床。从模具技术的发展开始，将成形操作集成到机器中，研究单点增量成形过程产生的粉末喷嘴在受凹槽影响的平面和曲面上的添加剂沉积。混合部件将进行机械测试和微观结构研究，样品和测试设备必须开发。单点增量成形应以这样一种方式进行调节，就制造和性能而言，可以创建优化的基材基础，从而为添加剂沉积物提供最佳的粘合。在增材制造领域，应该研究粉末喷嘴路径策略必须如何适应全局（粉末喷嘴到基材的操作距离）或局部（凹槽深度的尺寸）。因此，应探索这种新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。

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.