Interrupted hybrid manufacture (IHYM)

中断混合制造 (IHYM)

• 批准号: 103457
• 金额: $ 189.4万
• 依托单位: DMG MORI UK LIMITED
• 依托单位国家: 英国
• 项目类别: Collaborative R&D
• 财政年份: 2018
• 资助国家: 英国
• 起止时间: 2018 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=103457
• 关键词: Interrupted; hybrid; manufacture; IHYM

The vision is to develop single platform machine for Interrupted HYbrid additive / subtractive Manufacture with integrated inspection technologies -- for the purposes of this bid, defined as IHYM. This will be based on blown powder additive and 5-axis mill-turn machining. We will develop process capability in four application areas where we have identified a business need:§ Interrupted processing: the creation of complex internal geometries which can only be achieved through IHYM.§ 'Lumps and bumps': Working with slimline forgings or castings and adding external features such as bosses, elbows or ribs to improve material yield and enable rapid customisation of products.§ Graded Functionality: control localised material properties through control of lay conditions in conjunction with bulk material - single or multi material.§ Titanium: process redesign to enable IHYM with TitaniumTo deliver these additive capabilities, real-time process information must be obtained and mined for insights. Process monitoring will be linked to real-time or event-based control of the platform through a novel rule-based system which will provide both user feedback and increased machine autonomy. A completely new field is the development of combined process models which will provide insights into the effect of IHYM on part metallurgy. A novel feature-based cost modelling system will also be developed.The project starts at a manufacturing readiness level (MRL) 4 and using the market-leading hybrid platform from DMG Mori, and will deliver hybrid machining techniques to MRL6 for four additive capabilities. Key objectives and innovative developments are:§ Novel through-process models and decision systems§ Through-process monitoring and control, fed by insights from models§ Connected system to fuse knowledge and rules with data analytics§ Completely new IHYM ability for Titanium§ Manufacturing strategy for intermittent deposition / machining due to heating and cooling effects§ Manufacturing capability for graded materials§ Development of adjacent processes (powder characterisation and recommendations for standards, novel heat treatments)§ Design rules for IHYMProject impacts include:§ Acceleration of IHYM uptake because of the automated decision tool and cost model§ Reduced material consumption in aerospace and oil and gas components by 60%, linked to the near-net additive manufacture of raw components, thereby replacing or simplifying castings and forgings.§ Reduced tooling and associated costs.§ 30% reduction in production costs due to the introduction of IHYM technologies, linked to optimised manufacturing conditions and tool path optimisation.

我们的愿景是开发单一平台的机器中断混合添加剂/减制造与集成检测技术-为本投标的目的，定义为IHYM。这将基于吹制粉末添加剂和5轴铣削车削加工。我们将在四个已确定业务需求的应用领域开发工艺能力：§中断加工：创建复杂的内部几何形状，这只能通过IHYM实现。§“块和凸块”：处理细长锻件或铸件，并添加凸台、弯头或肋等外部特征，以提高材料产量，并实现产品的快速定制。通过控制铺设条件结合散装材料（单一或多种材料）来控制局部材料特性。§钛：重新设计工艺，使IHYM能够使用钛为实现这些附加功能，必须获取实时工艺信息并进行深入挖掘。过程监控将通过一个新颖的基于规则的系统与平台的实时或基于事件的控制相联系，该系统将提供用户反馈和增加的机器自主性。一个全新的领域是开发组合工艺模型，这将为IHYM对零件冶金的影响提供见解。该项目从制造就绪水平（MRL）4开始，使用市场领先的DMG Mori混合平台，并将为MRL 6提供混合加工技术，以实现四种增材能力。主要目标和创新开发包括：§新颖的全过程模型和决策系统§从模型中获得的见解提供的全过程监控和控制§将知识和规则与数据分析相融合的连接系统§针对钛的全新IHYM能力§由于加热和冷却效应而针对间歇沉积/加工的制造策略§针对梯度材料的制造能力§相邻工艺的开发（粉末特性和标准建议，新型热处理）§ IHYM项目影响的设计规则包括：§由于采用了自动化决策工具和成本模型，IHYM的采用速度加快了§航空航天和石油天然气部件的材料消耗减少了60%，与原材料零部件的近净增材制造相关联，从而替代或简化铸件和锻件。§减少工具和相关成本。§由于引入IHYM技术，与优化的制造条件和刀具路径优化相关联，生产成本降低30%。