Innovative Process Planning Strategies for Bead Deposition Based Additive Manufacturing Processes

增材制造（AM）方法由无工具工艺组成，可以通过连续分层二维（2D）材料的横截面来生产复杂的三维（3D）零件和组件。增材制造流程正变得越来越普遍；然而，支持“一般系统配置”（即机床或机器人单元）的设计和制造活动的工艺规划解决方案是有限的，并且基于头的沉积AM工艺的虚拟仿真工具也有限。机器人和通用机床制造商正在开发用于增材制造大型多材料部件的设备，但目前还没有材料-工艺-部件库，也没有现成的综合制造策略。从本质上讲，正在开发使用增材制造方法制造组件的专业系统，但很少有制造商知道如何有效地使用它们。拟议的研究计划将侧重于了解过程特性，以扩展和优化“过程建模，规划和验证”机会，这可以支持各种增材制造平台，并与加工平台集成。与研究相辅相成的是为工业社区开发设计工具，这将使新的制造机会得以实现。目标应用是材料挤压，线弧和激光熔覆的增材制造元件。混合制造，将材料添加和减少（加工）操作结合起来创建最终的工艺计划，将在本研究中进行研究******由于材料在沉积和固化时发生剧烈的加热和冷却循环，工艺规划解决方案应考虑这些热特性。众所周知，由于热流的变化，在铸造和焊接过程中会发生变形，这一现象需要在增材制造过程中进行探索，并且需要开发工艺规划解决方案来管理这些问题。******通过创建新的刀具路径选项，以及独特的平面和非平面行程路径策略，挑战“恒定头宽”和2D“分层”范式的技术将得到开发。这将解决与增材制造头沉积工艺相关的挑战和机遇******混合制造，其中材料以“近净形状”沉积，然后进行加工，为工艺规划策略引入了一个新的维度。这一研究领域还需要深入探索，因为机床公司正在开发具有该功能的设备，但没有知识库来利用这些设备的功能。******据预测，到2025年，全球对AM的影响将超过5000亿美元。这项研究将有助于开发HQP，并为从事先进AM活动的加拿大人提供相关解决方案。**

Additive Manufacturing (AM) methods consist of tool-less processes that can produce complex three dimensional (3D) parts and assemblies by successively layering two dimensional (2D) cross-sections of material. AM processes are becoming more common; however, there are limited process planning solutions to support design and manufacturing activities for ‘general system configuration' (i.e. machine tool or robot cell) bead based deposition AM processes, and there are limited virtual simulation tools. Robotic and general machine tool manufacturers are developing equipment to additively manufacture large, multi-material components, but there are no material-process-component libraries and no comprehensive building strategies readily available. Essentially, specialty systems are being developed to fabricate components using AM approaches, but very few manufacturers know how to effectively use them. The proposed research program will focus on understanding process characteristics to expand and optimize 'Process Modelling, Planning and Verification' opportunities, which can support a variety of AM platforms, and integrate with machining platforms. Complementing the research is the development of design tools for the industrial community that will enable new manufacturing opportunities to be realized. The target applications are material extrusion, wire arc, and laser cladding for the additive manufacturing element. Hybrid manufacturing, where material addition and subtraction (machining) operations are combined to create the final process plan, will be investigated in this research******As aggressive heating and cooling cycles occur when materials are being deposited and solidified, process planning solutions should consider these thermal characteristics. It is well known that distortion occurs in casting and welding processes due to variations in heat flow - this phenomenon needs to be explored for AM processes, and process planning solution alternatives to manage these issues need to be developed. ******Techniques to challenge the ‘constant bead width' and the 2D ‘layering' paradigms by creating new tool path options, and unique planar and non-planar travel path strategies will be developed. This will address both the challenges and leverage the opportunities associated with AM bead deposition processes ******Hybrid manufacturing, where material is deposited as a ‘near net shape', and then machined, introduces a new dimension for process planning strategies. This research area also needs to be explored in-depth, as machine tool companies are developing equipment capable of this functionality, but there is no knowledge base to leverage these equipments' capabilities.******It is predicted that the global impact for AM by 2025 will reach over $500 billion. This research will help develop HQP, and provide relevant solutions for Canadians engaged in advanced AM activities. **