Model-based mechanical design and process planing for incremental manufacturing of multi-material workpieces

产品的可变柔性是成本效率、材料效率和资源效率的综合结果。在具有复杂几何形状的工件的大批量批量生产中，经济上的成功和高生产率通常通过基于模具和成形工具的工艺原理来实现。这是特定于这样的过程，工件几何形状由工具的几何形状定义（例如：注塑成型，成型）。这是产品多样化（这意味着越来越多的变体）的痛苦后果，批量减少，因此对基于工具的技术的特定变体投资增加。 因此，迫切需要一种全新的生产概念，在保持提供大批量系列产品的能力的同时，显著减少变体的具体工作量。项目提案人通过将现有的制造工艺与增材制造工艺相结合来解决这个问题，以使这种技术组合能够用于功能化的多材料工件。在初步工作中，这一研究领域已由项目提案人进行了结构化和描述。 目前，实验基础设施正在开发中，并将在布伦瑞克工业大学（由DFG-Großgerät创立）的“增量制造实验室”中实现。“增量制造”的基本原理包括以高材料沉积速率对预制基础工件（例如预成型金属板、型材几何形状）进行基于机器人的增材定型，随后对其功能表面进行校准。这种新的制造理念将展示出大量生产多样化工件组合的新方法。然而，大量的自由度提出了关于产品和过程定义的基本研究问题。 本计画的目的是提出并详细阐述一种渐进式制造的工件与制造设计整合方法。部分增材制造多材料工件的设计原则和制造策略的确定对于利用增量制造的好处是必要的。

Variant flexibility of products is a consequencs of cost efficiency, material efficiency and resource efficiency. Economic success and high productivity in large volume series production of workpieces with complex geometry is commonly achieved through the principle of mold- and forming-tool-based processes. It is specific for such processes that the workpiece geometry is defined by the geometry of the tool (examples: injection molding, forming). It is a painful consequence of product diversification (which implies an increasing number of variants) that lot sizes decrease, so that variant specific invest in tool based technologies increases. There is hence a strong need for fundamentally new production concepts that attain significant reduction of variant specific effort while maintaining the capability to provide large volume series. The project proposers approach this problem by combining existing manufacturing processes with additive manufacturing processes for synergistically, in order to qualify this technology combination for functionalised multi-material workpieces. In preliminary work, this research area has been structured and described by the project proposers. Currently, experimental infrastructure is under development and will be realized in the “incremental manufacturing lab” at TU Braunschweig (founded by DFG-Großgerät). The fundamental principle of “incremental manufacturing” consists of robot-based additive finalization of prefabricated base workpieces (e.g. preformed sheet metal, profile geometries) with high material deposition rate and, subsequently, their calibration of the function surfaces. This new manufacturing concept shall show new ways of large volume series production of variant-rich workpiece portfolios. However, the large number of degrees of freedom raises fundamental research questions with respect to product and process definition. It is the aim of this project to propose and elaborate an integrated method for workpiece and manufacturing design for incremental manufacturing. The conjunction of design principles for partially additively manufactured multi-material workpieces and the determination of manufacturing strategies is necessary to exploit the benefits of incremental manufacturing.