Metal AM Process Informatics for Improved Surface Finish of Complex Parts

金属添加剂制造(AM)可产生接近净形状的复杂3D组件。零件的表面光洁度(SF)是不均匀的，表面粗糙度在设计的各个方面是可变的。对于一些工业部门的AM零件来说，使用标准的后处理方法可以获得的表面质量是不可接受的。这里的挑战是在AM生产过程中通过降低近净零件表面粗糙度的变化来提高金属AM零件的表面光洁度，并改进后处理(PP)技术以适应日益增加的AM零件的复杂性。该项目旨在开发一种创新的工艺优化系统，该系统可以将AMBuild参数与所生产的表面光洁度联系起来，以生成一个软件工具，供AM设计者用来选择最佳参数来为单个AM零件生成优化的表面光洁度，以及随后优化的后处理SF方法。这种方法将优化AM制造过程和ASPP技术，以实现所需表面光洁度的交付，增加行业对高价值AM部件的采用，在支持英国制造业创新的同时增加销售和就业。

Metal additive manufacturing (AM) creates complex 3D components at near net shape. Surface finish(SF) of theAM part is uneven, with surface roughness being variable over the facets of the design. The surface qualityachievable using standard post-processing methods is unacceptable for some industry sector AM part uptake.The challenge here is to improve metal AM part surface finish by decreasing the variability of surface roughnessof the near net-part during AM production and to improve post-processing (PP) techniques to suit increasedAM part complexity. This project aims to develop an innovative process optimisation system which can link AMbuild parameters to the surface finish produced to generate a software tool for AM designers to use to selectthe best parameters to generate an optimised surface finish for the individual AM part, and subsequentoptimised post-processing SF methodologies. This approach will optimise both the AM build process as well asPP techniques to enable the delivery of the required surface finishes, increase industrial adoption of high-valueAM parts, generating increased sales and employment while supporting UK manufacturing innovation.