NSF Young Investigator: Scanned Thermal Rapid Prototyping Processes

9457206 Doumanidis这项研究通过重新设计工艺安排和实施扫描的热驱动，解决了热快速成型中零件几何形状和热场的同时实时调节问题。在热快速成型中，由于连续的材料层被沉积或从零件表面移除，因此在该过程中，由送丝器或喷涂器提供的材料和由等离子体或激光光源进行的热传递都需要进行调制。分别用激光视觉系统和红外摄像机测量产品表面的层状几何形状和热分布，并反馈给热几何控制器。这将调整材料和热源的强度，并将它们在动态轨迹上的运动引导到最需要它们作用的区域，从而获得所需的几何公差、材料结构和性能以及零件的应力效应。校准后的控制器将在几种快速成型技术上进行实验实现，即分层实体制造、激光铣削、熔融材料沉积和热喷射沉积。这项研究还将与支持性教学活动相结合，丰富大学的热制造课程。这些措施包括建立一个研究生制造自动化研讨会，并提供客座讲座和工业赞助。还将在实验室开发一系列激励人心的入门课程，包括多学科制造内容和动手制作原型项目。

9457206 Doumanidis The research addresses the issue of simultaneous, real-time regulation of part geometry and thermal field, in thermal rapid prototyping, by redesigning the process arrangement and implementing a scanned thermal actuation. In thermal rapid prototyping, both the material supply, by a wire feeder or spray, and heat transfer, by a plasma or laser source, need to be modulated during the process as successive layers of material are deposited or removed from the part surface. The layer profile geometry and thermal distribution on the product surface will be measured by a laser vision system, and an infrared camera respectively, and used for feedback to the thermo-geometrical controller. This will adjust the material and heat source intensity and guide their motion on dynamic trajectories to the areas where their action is needed most, so as to obtain the desired geometric tolerances, the material structure and properties, and stress effects in the part. The calibrated controller will be implemented experimentally on several rapid prototyping techniques, i.e. laminated object manufacturing, laser milling, fused material deposition and thermal spray deposition. The research will also be coupled to supportive teaching activities, enriching the thermal manufacturing curriculum at the university. These include the establishment of a graduate manufacturing automation seminar with guest lectures and industrial sponsorship. A series of motivating introductory courses will also be developed, with multidisciplinary manufacturing content and hands-on prototyping projects, in the laboratory.