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

基于模型的机械设计和多材料工件增量制造工艺规划

• 批准号: 412330610
• 负责人: Professor Dr.-Ing. Klaus Dröder
• 金额: --
• 依托单位: Institut für Konstruktionstechnik
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2018
• 资助国家: 德国
• 起止时间: 2017-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/412330610?language=en
• 关键词: Model; based; mechanical; design; process

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.

产品的可变柔性是成本效率、材料效率和资源效率的结果。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是通过基于模具和成形工具的工艺原理来实现的。工件的几何形状是由工具的几何形状来定义的，这是特定于这些工艺的（例如：注射成型、成形）。这是产品多样化的一个痛苦的结果（这意味着变体数量的增加），批量大小减少，因此基于工具技术的变体特定投资增加。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的能力的同时，显著减少变体的具体工作量。项目发起人通过将现有制造工艺与增材制造工艺相结合来协同解决这个问题，以便使这种技术组合具有功能化多材料工件的资格。在初步工作中，该研究领域已由项目提案人进行了结构和描述。目前，实验基础设施正在开发中，并将在不伦瑞克工业大学的“增量制造实验室”（由DFG-Großgerät创立）中实现。“增量制造”的基本原理包括基于机器人的高材料沉积速率预制基本工件（例如预制金属板，轮廓几何）的增材定型，以及随后对功能表面的校准。这种新的制造理念将为大批量批量生产多种工件组合提供新的途径。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。本课题的目的是提出并阐述一种面向增量制造的工件与制造设计的集成方法。多材料零件部分增材制造的设计原则与制造策略的确定相结合是充分发挥增量制造优势的必要条件。