Innovative Process Planning Strategies for Bead Deposition Based Additive Manufacturing Processes

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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. **