MRI: Development of a Five-Axis Rapid Metal Forming System

该拨款为使用激光应用金属加工的五轴快速金属成形设备的研究和开发提供资金。该设备将利用送丝系统来提高沉积金属的速度和准确性。将开发集成软件，用于自动生成五轴直接金属加工的工艺规划。该工厂将能够直接生产铁合金和有色合金的金属原型和零件。研发活动将包括开发和优化五轴金属成形系统的多轴路径规划；基于视觉处理的激光沉积控制激光沉积机的智能路径规划与控制影响零件微观组织的沉积因素研究快速成形金属件质量优化的过程控制研究输运现象提高激光沉积质量并采用直接金属成形工艺，使产品快速实现。这个项目将导致快速形成金属原型的能力。设计师将能够生成具有功能分级材料的近净形状零件的CAD图纸，以匹配设计要求，然后使用该设备在几个小时内直接生产金属原型。如果成功，零件将以高精度和出色的再现性生产。在沉积过程中可以优化零件的组织和性能。这将为许多需要快速金属原型的制造商提供好处，例如工具和模具行业，其交货时间传统上是几周。这将使制造商受益，缩短产品开发周期，并向市场提供更好的产品。一体化的教研培训活动，将前沿科学技术带入课堂。

This grant provides funding for the research and development of a five-axis rapid metal forming facility using laser applied metal processing. The equipment will utilize a wire feeding system to improve the speed and accuracy of depositing metal. Integration software will be developed for automated generation of process planning for five-axis direct metal process. The facility will be capable of directly producing metal prototypes and parts from both ferrous and non-ferrous alloys. Research and development activities will include developing and optimizing multi axis path planning for a five-axis metal forming system; vision-based processing for control of laser deposition; intelligent path planning and control of laser deposition machines; studies of deposition factors determining part microstructure; process control for optimizing quality of rapidly formed metal parts; studies of transport phenomena to improve laser deposition quality; and applying the direct metal forming process to allow for rapid product realization. This project will result in the ability to rapidly form metal prototypes. Designers will be able to generate CAD drawings of a near-net shape part with functionally graded materials to match design requirements and then use this equipment to directly produce a metal prototype within a few hours. If successful, the parts will be produced with high accuracy and excellent reproducibility. The microstructure and properties of the parts can be optimized during the deposition process. This will provide a benefit to many manufacturers that require rapid metal prototypes such as the tool and die industry where lead times are traditionally several weeks. The will benefit manufacturers by shortening product development cycle times and delivering better products to market. The integrated educational and research training activities will bring cutting-edge science and technology to the classroom.