Process combination of single point incremental forming and laser powder deposition for the manufacturing of lightweight components

现有的通过成形方法或添加制造技术来制造部件的方法都有相当大的缺点。通过在一台机器上创新地结合单点渐进成形和附加制造两种工艺，将两种制造领域的优势融合在一起，生产出功能高度集成的轻量化部件。在成形方法中，单点渐进成形提供了以小批量覆盖大范围部件的机会，而无需使用特定于产品的模具。部件具有壳状特征，并且主要用于覆盖较大的区域，例如用作结构部件。通过激光粉末沉积的附加制造，可以单独和局部地添加几何特征，从而使优化的功能适应轻量化设计成为可能，同样不需要使用特定于产品的模具。新型工艺组合的开发和基础研究的技术基础是东风集团资助研制的五轴联动加工中心加减组合加工的新型机床。从模具技术的发展入手，研究了单点渐进成形过程中，粉末喷嘴在平面和曲面上的附加沉积问题。混杂部件将进行机械测试，并利用必须开发的样品和测试设备进行微观结构研究。单点渐进成形应以这样一种方式进行调整，即在制造和性能方面，创建优化的基板，从而允许对添加沉积进行尽可能好的结合。在添加剂制造领域，应该研究如何使粉末喷嘴路径策略在整体上(粉末喷嘴到基材的工作距离)或局部(在凹槽深度方面)适应。因此，应该探索这种新的工艺组合和产品组的基本原理和技术限制，并评估在能源和资源高效制造方面的潜力。

The existing approaches for the manufacturing of components either by means of forming methods or additive manufacturing technologies result in considerable disadvantages each. By an innovative combination of the two processes single point incremental forming and additive manufacturing in one machine, the advantages of both manufacturing worlds are merged for the production of lightweight components with a high integration of functions. Among the forming methods, the single point incremental forming offers the opportunity to cover a large range of components in small batch sizes without using product-specific dies. The components have a shell-like character and serve principally for covering large areas, e.g. functioning as structural components. Via additive manufacturing by laser powder deposition geometrical features can be added individually and locally, making an optimized functional adapted lightweight design of components with a high quality lightweight design possible, again without using product-specific dies. The technological basis for the development and fundamental research of the novel process combination is a new machine for the combined additive and subtractive manufacturing in a 5-axis machining center, funded by the DFG. Beginning with the development of the die technology for the integration of the forming operations into the machine, the additive deposition with the powder nozzle on the plane and curved surfaces afflicted with grooves, resulting from the single point incremental forming process, shall be investigated. The hybrid parts will be tested mechanically and investigated microstructurally with samples and test devices which have to be developed. The single point incremental forming shall be conditioned in such a way that, in terms of the manufacturing and the properties, an optimized substrate base is created, which allows the best possible bond for the additive deposit. In the field of additive manufacturing it should be examined how the powder nozzle path strategy must be adapted globally (operating distance of the powder nozzle to the substrate) or also locally (in the dimension of the groove depth). As a result, the fundamentals and the technological limits for this novel process combination and product group shall be explored and the potential, in regard to an energy and resource efficient manufacturing, shall be evaluated.