Interrupted hybrid manufacture (IHYM)

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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.