Expanding the additive manufacturing process paradigm thorough the investigation of novel product design and process planning techniques

增材制造（AM）方法能够从连续的二维（2D）材料横截面分层生产复杂的三维（3D）零件和组件，以创建最终组件。增材制造流程正变得越来越普遍；然而，在产品和过程级别上有独特的机会可以利用。过程规划控制很少，虚拟仿真工具有限。拟议研究计划的目标是开发和优化熔融沉积建模（FDM）和激光熔覆工艺的“产品设计”和“过程建模和验证”机会。考虑到产品形式、工艺参数和使用实验设计方法来理解关键控制元素的构建策略，将探索可实现的制造精度。众所周知，由于热流的变化，在铸造和焊接过程中会发生变形，这一现象需要在增材制造过程中进行探索，并需要开发解决方案。例如，对于FDM工艺，建议采用独特的3D参数化内部结构（即蜂窝或网格）来优化构建时间，强度和材料使用，并控制变形。然后可以为给定的应用程序和AM技术（例如大型FDM组件的装配设计）开发设计指南，同时考虑可实现的构建精度，强度和制造时间。这将通过开发过程建模和验证工具得到补充。在当代分层制造方法之外，还有一些可以实现的机会，例如探索AM等效的粗加工和精加工，以及开发包含旋转定位的刀具路径（激光熔覆工艺）。虚拟现实建模工具将用于开发仿真模型。这项研究将导致开发与增材制造工艺相关的新的和未实现的先进设计和制造机会，以及在增材制造环境中开发和商业化新型增材制造工艺模块。

Additive manufacturing (AM) methods are capable of producing complex three dimensional (3D) parts and assemblies from layering two dimensional (2D) cross sections of material successively to create the final components. AM processes are becoming more common; however, there are unique opportunities to be exploited at the product and process levels. There is little process planning control, and limited virtual simulation tools. The objectives of the proposed research program are to develop and optimize 'Product Design' and 'Process Modeling and Verification' opportunities for the Fused Deposition Modelling (FDM) and laser cladding processes. The achievable fabrication accuracies will be explored considering the product form, process parameters and build strategies using a Design of Experiments approach to understand the key control elements. It is well known that distortion occurs in casting and welding processes due to variations in heat flow - this phenomenon needs to be explored for AM processes, and solution alternatives need to be developed. For example for the FDM process, it is proposed to employ unique 3D parametric internal structures (i.e., honeycomb or grid) to optimize build time, strength and material usage, and control distortion. Design guidelines can then be developed for a given application and AM technology such as Design for Assembly for large FDM components, while considering achievable build accuracies, strength and the fabrication time. This will be complemented by developing process modeling and verification tools. There are opportunities that can be realized outside of the contemporary layered manufacturing approach, such as exploring the AM equivalent of roughing and finishing, and developing tool paths that incorporate rotary positioning (laser cladding process). Virtual reality modeling tools will be employed for developing the simulation models. This research will result in developing new and unrealized advanced design and manufacturing opportunities related to AM processes, as well as the development and commercialization of novel AM process modules within a CAM environment.