Model-based mechanical design and process planing for incremental manufacturing of multi-material workpieces

产品的变型柔性是成本效率、材料效率和资源效率的结果。在大批量系列化生产复杂几何形状的零件时，经济上的成功和高生产率通常是通过基于模具和成形工具的工艺原理实现的。对于这样的工艺，工件的几何形状是由工具的几何形状定义的(例如：注塑、成型)。产品多样化(这意味着变种的数量越来越多)的痛苦后果是批量减少，因此特定变种对基于工具的技术的投资增加。因此，迫切需要从根本上实现新的生产概念，在保持提供大批量系列的能力的同时，显著减少变种的特定工作量。项目提出者通过将现有制造工艺与附加制造工艺相结合来解决这一问题，以便将这一技术组合应用于功能化多材料零件。在前期工作中，这一研究领域已经由项目建议书进行了组织和描述。目前，实验基础设施正在开发中，将在TU Braunschweig的“增量制造实验室”(由DFG-Groçgerät创建)实现。“增量制造”的基本原理是基于机器人对具有高材料沉积速率的预制基础零件(例如预制板材、型材几何形状)进行加法定型，并随后对其功能表面进行校准。这一新的制造概念将展示大批量系列化生产各种不同的零件组合的新方法。然而，大量的自由度引发了关于产品和过程定义的基础性研究问题。本项目的目的是提出并阐述一种面向增量制造的零件与制造设计的集成方法。为了利用增量制造的好处，必须将部分附加制造的多材料零件的设计原则与制造策略的确定相结合。

Variant flexibility of products is a consequencs of cost efficiency, material efficiency and resource efficiency. Economic success and high productivity in large volume series production of workpieces with complex geometry is commonly achieved through the principle of mold- and forming-tool-based processes. It is specific for such processes that the workpiece geometry is defined by the geometry of the tool (examples: injection molding, forming). It is a painful consequence of product diversification (which implies an increasing number of variants) that lot sizes decrease, so that variant specific invest in tool based technologies increases. There is hence a strong need for fundamentally new production concepts that attain significant reduction of variant specific effort while maintaining the capability to provide large volume series. The project proposers approach this problem by combining existing manufacturing processes with additive manufacturing processes for synergistically, in order to qualify this technology combination for functionalised multi-material workpieces. In preliminary work, this research area has been structured and described by the project proposers. Currently, experimental infrastructure is under development and will be realized in the “incremental manufacturing lab” at TU Braunschweig (founded by DFG-Großgerät). The fundamental principle of “incremental manufacturing” consists of robot-based additive finalization of prefabricated base workpieces (e.g. preformed sheet metal, profile geometries) with high material deposition rate and, subsequently, their calibration of the function surfaces. This new manufacturing concept shall show new ways of large volume series production of variant-rich workpiece portfolios. However, the large number of degrees of freedom raises fundamental research questions with respect to product and process definition. It is the aim of this project to propose and elaborate an integrated method for workpiece and manufacturing design for incremental manufacturing. The conjunction of design principles for partially additively manufactured multi-material workpieces and the determination of manufacturing strategies is necessary to exploit the benefits of incremental manufacturing.