MRI: Acquisition of a Solid Freeform Fabrication Laboratory for Interdisciplinary Research and Education in Manufacturing through a University/Industry Consortium

这笔赠款为购买激光工程净成形（透镜）系统和熔融沉积成型（FDM）单元提供资金，用于固体自由成形制造（SFF）的跨学科研究和教育。该研究的主要目标是开发基于科学的加工和微观结构模型，以帮助将透镜从概念验证阶段推向工业的全面实施。加工模型将被开发用于预测热流、最小化残余应力和变形、控制微观结构和优化刀具路径规划。透镜单元将用于模型验证和加工算法的开发，以控制微观结构和最大限度地减少变形。还将通过基于模型和实验的活动研究沉积具有分级微观结构和性能的组件的方法。将评估粉末性质对流动均匀性的作用，并将评价透镜工艺，以确定相对于竞争SFF工艺的优势和局限性。这些仪器将通过本科课程教学用于教育。在这项教育工作中，FDM单元将由材料，机械和工业工程系的本科生在综合制造课程中使用，以从计算机辅助绘图中创建实体模型。一旦创建了实体模型，透镜单元将用于准备性能测试的功能原型。参与的工程部门将共同开发关于快速成型和SFF的新教学模块，以支持新设备。通过这些努力，将开发通用模型和算法，供最终用户用于工艺优化，以避免透镜制造的“试错法”。这项研究的结果将被工业合作伙伴用于制造部件，减少制造时间，提高尺寸精度，并为增强性能量身定制。教育活动将教本科生如何应用材料，机械和工业工程的基本概念，使用SFF工艺制造组件。

This grant provides funding for the purchase of a Laser Engineered Net Shaping (LENS) system and a Fused Deposition Modeling (FDM) unit for interdisciplinary research and education in Solid Freeform Fabrication (SFF). The primary objective of the research is to develop science-based processing and microstructure models that will aid in moving LENS from the proof-of-concept stage towards full scale implementation by industry. Processing models will be developed for predicting heat flow, minimizing residual stress and distortion, controlling microstructure, and optimizing tool path planning. The LENS unit will be used for model validation and development of processing algorithms for controlling microstructure and minimizing distortion. Methods for depositing components with graded microstructures and properties will also be investigated through both model and experimental based activities. The role of powder properties on flow uniformity will be assessed, and the LENS process will be evaluated to identify advantages and limitations relative to competing SFF processes. The instruments will be used for education through undergraduate course instruction. In this educational effort, the FDM unit will be used by undergraduates in the Materials, Mechanical, and Industrial Engineering Departments in an integrated manufacturing course to create solid models from computer aided drawings. Once solid models are created, the LENS unit will then be used to prepare functional prototypes for performance testing. New instruction modules on rapid prototyping and SFF will be developed jointly between the participating engineering departments to support the new equipment.From these efforts, generic models and algorithms will be developed that can be applied by end users for process optimization in order to avoid "trial and error" approaches to LENS manufacturing. The results of this research will be used by industrial partners to fabricate components with reduced manufacturing time, improved dimensional accuracy, and properties that are tailored for enhanced performance. The educational activities will teach undergraduate students how to apply basic concepts in materials, mechanical, and industrial engineering to manufacture components using SFF processes.