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

添加制造(AM)方法能够通过连续地将材料的二维(2D)横截面分层来生产复杂的三维(3D)部件和组件，以产生最终的部件。AM过程正变得越来越普遍；然而，在产品和过程层面上有独特的机会可供开发。几乎没有工艺规划控制，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成型(FDM)和激光熔覆工艺的“产品设计”和“工艺建模和验证”机会。考虑到产品形状、工艺参数和构建策略，将使用实验设计方法来探索可实现的制造精度，以了解关键控制元素。众所周知，由于热流的变化，铸造和焊接过程中会发生变形--这一现象需要在AM工艺中进行探索，并需要开发解决方案。例如，对于FDM工艺，建议使用独特的3D参数内部结构(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，可以针对给定的应用和AM技术(如大型FDM组件的装配设计)制定设计指南，同时考虑可实现的制造精度、强度和制造时间。将通过开发流程建模和核查工具来补充这一点。除了当代的分层制造方法之外，还有一些机会可以实现，例如探索AM等效于粗加工和精加工的方法，以及开发包含旋转定位(激光熔覆工艺)的刀具路径。使用虚拟现实建模工具开发仿真模型。这项研究将导致开发与AM工艺相关的新的和未实现的先进设计和制造机会，以及在CAM环境中开发和商业化新型AM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.