Innovative Process Planning Strategies for Bead Deposition Based Additive Manufacturing Processes

基于珠沉积的增材制造工艺的创新工艺规划策略

• 批准号: RGPIN-2018-04842
• 负责人: Urbanic, Ruth
• 金额: $ 1.97万
• 依托单位: University of Windsor
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2020
• 资助国家: 加拿大
• 起止时间: 2020-01-01 至 2021-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=713295
• 关键词: Innovative; Process; Planning; Strategies; Bead

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.

增材制造（AM）方法由无工具工艺组成，其可以通过连续层叠材料的二维（2D）横截面来生产复杂的三维（3D）部件和组件。AM工艺正变得越来越普遍;然而，存在有限的工艺规划解决方案来支持用于一般系统配置（即，机床或机器人单元）的基于珠的沉积AM工艺的设计和制造活动，并且存在有限的虚拟仿真工具。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组件的设备，但没有材料-工艺-组件库，也没有现成的综合构建策略。从本质上讲，正在开发专业系统来使用AM方法制造组件，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，以扩大和优化“过程建模，规划和验证”的机会，这可以支持各种AM平台，并与加工平台集成。作为对研究的补充，工业界开发了设计工具，这将使新的制造机会得以实现。目标应用是增材制造元件的材料挤出、电弧焊和激光熔覆。混合制造，其中材料的添加和减少（加工）操作相结合，以创建最终的工艺计划，将在本研究中进行调查 由于材料沉积和固化时会发生剧烈的加热和冷却循环，因此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-需要针对AM过程探索这种现象，并且需要开发管理这些问题的工艺规划解决方案替代方案。 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，将开发挑战恒定焊道宽度和2D分层范例的技术。这将解决与AM微珠沉积工艺相关的挑战并利用机遇 混合制造，其中材料被沉积为近净形状，然后加工，为工艺规划策略引入了新的维度。这一研究领域也需要深入探索，因为机床公司正在开发能够实现这一功能的设备，但没有知识库来利用这些设备的功能。 据预测，到2025年，AM的全球影响将达到5000亿美元以上。这项研究将有助于发展HQP，并为从事先进AM活动的加拿大人提供相关的解决方案。