Functionally Determinated Additive Manufacturing

附加制造(AM)提供了摆脱传统制造工艺的许多限制的机会。然而，AM工艺也给设计、工艺准备和功能部件几何形状的生产带来了新的限制和挑战。通过在给定的构建方向上连续添加材料，可以将零部件创建为生长实体。逐层制造策略将各向异性行为印在组件上，并严重限制了复杂几何图形的可打印性，因为设计通常无法避免不利的力状态和较差的可打印活动表面。所述项目的优越研究假设是：通过跨学科的面向功能、多方向和无层的产品开发过程，可以以面向载荷的方式设计和制造为加法制造优化的零部件几何形状，并具有功能优化的活动表面。该项目的总体目标是通过建立由设计过程、过程准备和制造组成的连续产品开发过程(PDP)，并通过将熔合层建模(FLM)过程进一步发展为多方向的无层制造过程，来充分利用AM的潜力。子目标1.本设计的目的是为添加剂制造提供功能确定的部件设计。部件的功能由其活动表面和导向支承结构来表示。AM的自由度允许零部件的设计与所需的活动曲面和结构特征一致对齐。先决条件是面向功能的、基于模型的开发过程，该过程将活动曲面和结构特征放置在前景中，并考虑AM特定的制造限制。2.工艺准备的目标是一种算法，该算法根据最初与工艺无关的设计部件描述，考虑工艺特定的边界条件和所使用的机械手，计算出力路径优化制造所需的挤压轨迹。3.制造的目标是一种典型的6D打印和处理工艺，该工艺以空间和负载优化的方式应用挤压线，并能够灵活地抓住、保持和引导所产生的部件。这一制造过程由由固定打印头和机器人组成的演示器实现。固定打印头确保挤出线始终处于平坦的位置(与打印面水平)。机器人轨迹的规划允许机器人在打印头下以最大的自由度连续操作部件。

Additive Manufacturing (AM) offers the opportunity to leave many limitations of conventional manufacturing processes behind. However, AM processes also bring new constraints and challenges for design, process preparation and the production of functional component geometries. Components are created as growing solid bodies by successively adding material in a given build direction. The layer-by-layer manufacturing strategy imprints anisotropic behavior on the component and severely limits the printability of complex geometries, since unfavorable force states and poorly printable active surfaces generally cannot be avoided by the design. The superior research hypothesis for the described project is: Through a cross-disciplinary function-oriented, multi-directional and layerless product development process, component geometries optimized for additive manufacturing can be designed and manufactured in a load-oriented manner and with functionally optimized active surfaces. The overall objective of the project is to harness the full potential of AM by establishing a continuous product development process (PDP) consisting of design process, process preparation and manufacturing and by further developing the Fused Layer Modelling (FLM) process into a multi-directional and layerless manufacturing process. Subgoals 1. The aim of the design is the functionally determined component design for additive manufacturing. The function of a component is represented by its active surfaces and its guiding-support structure. The degrees of freedom of AM allow the design of a component to be consistently aligned with the required active surfaces and structural features. The prerequisite is a function-oriented, model-based development process that places the active surfaces and structural features in the foreground and considers the AM-specific manufacturing restrictions. 2. The goal of process preparation is an algorithm that calculates the necessary extrusion trajectories for force-path-optimized manufacturing from the initially process-independent component description of the design, considering process-specific boundary conditions and the manipulator used. 3. The goal of manufacturing is a prototypical 6D printing and handling process that applies extrusion strands in a spatially and load-optimized manner and can flexibly grip, hold and guide the resulting component. This manufacturing process is realized by a demonstrator consisting of a fixed print head and a robot. The fixed print head ensures that extrusion strands are always applied in a flat position (horizontal to the print surface). The planning of the robot trajectory allows continuous manipulation of the component by the robot under the print head with maximized freedom.