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

增材制造（AM）方法能够通过连续地层叠二维（2D）材料横截面来生产复杂的三维（3D）部件和组件以创建最终部件。增材制造过程变得越来越普遍;然而，在产品和过程层面上有独特的机会可以利用。工艺规划控制很少，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“工艺建模与验证”机会。可实现的制造精度将探索考虑产品形式，工艺参数和构建策略，使用实验设计方法来了解关键控制元素。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-需要针对AM过程探索这种现象，并且需要开发解决方案替代方案。例如，对于FDM工艺，建议采用独特的3D参数内部结构（即，蜂窝或网格），以优化构建时间、强度和材料使用，并控制变形。然后可以为给定的应用和AM技术开发设计指南，例如大型FDM组件的装配设计，同时考虑可实现的构建精度，强度和制造时间。这将通过开发流程建模和验证工具来补充。在当代分层制造方法之外，还有一些机会可以实现，例如探索粗加工和精加工的AM等效方法，以及开发包含旋转定位（激光熔覆工艺）的刀具路径。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新的和未实现的先进设计和制造的机会，相关的AM过程，以及开发和商业化的新AM过程模块在CAM环境。

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.