A robotic metal hybrid additive and subtractive manufacturing system

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Growing demand for the use of cutting-edge metal materials to develop and repair large, complex structures in the aerospace, automotive, and energy sectors has necessitated the development of a low-cost manufacturing process. Additive manufacturing that laminates materials to create the desired workpiece shape has been in the spotlight because it can address a variety of geometric challenges such as interior and overhanging features and parts with a high "buy-to-fly" ratio. Currently, however, additive manufacturing yields low surface finishes, non-uniformly deposited layers, high material costs, long process times, and restricted-size components. This research program proposes to a state-of-art system that can simultaneously cut the uneven layers by collaborating manipulators during the additive process in order to overcome these challenges. Hybrid manufacturing, which combines the conventional subtractive manufacturing process with the additive process, enables us to use relatively cheap solid wire materials instead of expensive powder materials. This change reduces production lead time and improves surface quality by rapidly cutting the uneven surfaces of laminated materials within a short period. The platform for these processes, which consists of manipulators, can be a cost-saving, configuration-flexible, and multi-dimensional alternative. Consequently, combining robotics, subtractive processes, and additive processes into a single technology can synergize cost, process time, quality, and complexity. Large-sized parts applied with expensive materials, like stiffened panels, wing ribs, gas turbines, and pipelines, require an innovative manufacturing process to reduce cost and time. The long-term objective of this research proposal is to achieve the necessary technologies to build a robotic metal hybrid additive and subtractive manufacturing system. The proposed short-term objectives of this research are to understand the dynamics of the system and to improve upon the manipulators' current structural challenges. The robotic metal hybrid manufacturing system itself is novel. The automatic identification methods, the mode coupling effects analysis, and the self-adjustable vibration reduction device are also novel. This proposal's outcomes will be an automatic identification module, stability maps to increase process efficiency, and a self-tunable device. The technological outcomes achieved through the proposed program will enhance Canada's manufacturing technology, serve as catalysts for other novel applications and developments, and promote technology transfer to industry partners. This research is essential for the interdisciplinary training of highly-qualified personnel, who will learn about system design, dynamics, mechatronics, vibration, manufacturing, simulation, and control.