Interrupted hybrid manufacture (IHYM)

其愿景是开发具有集成检测技术的中断式混合增材/减材制造单平台机器，这是本次投标的目的，定义为IHYM。这将基于吹粉添加剂和5轴铣削加工。我们将在四个应用领域开发工艺能力，我们已经确定了业务需求：§中断处理：只能通过IHYM实现的复杂内部几何形状的创建。§“块状和凸起”：使用细长的锻件或铸件，并增加外部特征，如凸台，弯头或肋，以提高材料产量并实现产品的快速定制。§分级功能：通过控制与散装材料（单个或多个材料）相结合的铺设条件来控制局部材料特性。§钛：重新设计工艺，使IHYM与钛一起提供这些附加功能，必须获得实时工艺信息并挖掘洞察力。过程监控将通过一个新颖的基于规则的系统与平台的实时或基于事件的控制相关联，该系统将提供用户反馈和增强机器自主性。一个全新的领域是联合工艺模型的发展，这将为IHYM对零件冶金的影响提供见解。一个新的基于特征的成本建模系统也将被开发。该项目从制造准备水平（MRL） 4开始，使用市场领先的DMG Mori混合平台，并将为MRL6提供混合加工技术，用于四个增材能力。主要目标和创新发展是：新颖的全过程模型和决策系统；全过程监测和控制；通过模型的洞察提供支持。连接系统将知识和规则与数据分析相融合。全新的钛IHYM能力。由于加热和冷却效应，间歇沉积/加工的制造策略。分级材料的制造能力。相邻工艺的开发（粉末表征和标准建议）。IHYM项目影响的设计规则包括：由于自动化决策工具和成本模型，加速了IHYM的采用；由于原料部件的近净增材制造，航空航天和石油天然气部件的材料消耗减少了60%，从而取代或简化了铸件和锻件。减少加工和相关成本。§由于IHYM技术的引入，与优化的制造条件和刀具路径优化相关，生产成本降低了30%。

The vision is to develop single platform machine for Interrupted HYbrid additive / subtractive Manufacture with integrated inspection technologies -- for the purposes of this bid, defined as IHYM. This will be based on blown powder additive and 5-axis mill-turn machining. We will develop process capability in four application areas where we have identified a business need:§ Interrupted processing: the creation of complex internal geometries which can only be achieved through IHYM.§ 'Lumps and bumps': Working with slimline forgings or castings and adding external features such as bosses, elbows or ribs to improve material yield and enable rapid customisation of products.§ Graded Functionality: control localised material properties through control of lay conditions in conjunction with bulk material - single or multi material.§ Titanium: process redesign to enable IHYM with TitaniumTo deliver these additive capabilities, real-time process information must be obtained and mined for insights. Process monitoring will be linked to real-time or event-based control of the platform through a novel rule-based system which will provide both user feedback and increased machine autonomy. A completely new field is the development of combined process models which will provide insights into the effect of IHYM on part metallurgy. A novel feature-based cost modelling system will also be developed.The project starts at a manufacturing readiness level (MRL) 4 and using the market-leading hybrid platform from DMG Mori, and will deliver hybrid machining techniques to MRL6 for four additive capabilities. Key objectives and innovative developments are:§ Novel through-process models and decision systems§ Through-process monitoring and control, fed by insights from models§ Connected system to fuse knowledge and rules with data analytics§ Completely new IHYM ability for Titanium§ Manufacturing strategy for intermittent deposition / machining due to heating and cooling effects§ Manufacturing capability for graded materials§ Development of adjacent processes (powder characterisation and recommendations for standards, novel heat treatments)§ Design rules for IHYMProject impacts include:§ Acceleration of IHYM uptake because of the automated decision tool and cost model§ Reduced material consumption in aerospace and oil and gas components by 60%, linked to the near-net additive manufacture of raw components, thereby replacing or simplifying castings and forgings.§ Reduced tooling and associated costs.§ 30% reduction in production costs due to the introduction of IHYM technologies, linked to optimised manufacturing conditions and tool path optimisation.