A robotic metal hybrid additive and subtractive manufacturing system

航空航天、汽车和能源领域对使用尖端金属材料来开发和修复大型复杂结构的需求不断增长，这使得开发低成本制造工艺成为必要。叠层材料以创建所需工件形状的增材制造一直备受关注，因为它可以解决各种几何挑战，例如内部和悬垂特征以及具有高“购买-飞行”比率的零件。然而，目前，增材制造的表面光洁度低，沉积层不均匀，材料成本高，加工时间长，部件尺寸有限。为了克服这些挑战，本研究计划提出了一种先进的系统，该系统可以在添加过程中通过协作机械手同时切割不均匀层。混合制造将传统的减法制造工艺与增材制造工艺相结合，使我们能够使用相对便宜的固体线材而不是昂贵的粉末材料。这种变化减少了生产前置时间，并通过在短时间内快速切割层压材料的不均匀表面来提高表面质量。这些过程的平台由机械手组成，可以节省成本，配置灵活，并且是多维的替代方案。因此，将机器人技术、减法工艺和加法工艺结合到一个单一的技术中可以协同成本、工艺时间、质量和复杂性。采用昂贵材料的大型部件，如加劲板、翼肋、燃气轮机和管道，需要创新的制造工艺来降低成本和时间。这项研究计划的长期目标是实现必要的技术，以建立一个机器人金属混合增材和减材制造系统。本研究提出的短期目标是了解系统的动力学，并改进操纵者当前的结构性挑战。机器人金属混合制造系统本身是新颖的。自动识别方法、模态耦合效应分析和自调节减振装置也是新颖的。该提案的成果将是一个自动识别模块，稳定性图，以提高流程效率，和一个自调谐装置。通过拟议的项目取得的技术成果将提高加拿大的制造技术，作为其他新应用和发展的催化剂，并促进技术向工业伙伴的转移。这项研究对于培养系统设计、动力学、机电一体化、振动、制造、仿真和控制等方面的高素质人才至关重要。

Growing demand for the use of cutting-edge metal materials to develop and repair large, complex structures in the aerospace, automotive, and energy sectors has necessitated the development of a low-cost manufacturing process. Additive manufacturing that laminates materials to create the desired workpiece shape has been in the spotlight because it can address a variety of geometric challenges such as interior and overhanging features and parts with a high "buy-to-fly" ratio. Currently, however, additive manufacturing yields low surface finishes, non-uniformly deposited layers, high material costs, long process times, and restricted-size components. This research program proposes to a state-of-art system that can simultaneously cut the uneven layers by collaborating manipulators during the additive process in order to overcome these challenges. Hybrid manufacturing, which combines the conventional subtractive manufacturing process with the additive process, enables us to use relatively cheap solid wire materials instead of expensive powder materials. This change reduces production lead time and improves surface quality by rapidly cutting the uneven surfaces of laminated materials within a short period. The platform for these processes, which consists of manipulators, can be a cost-saving, configuration-flexible, and multi-dimensional alternative. Consequently, combining robotics, subtractive processes, and additive processes into a single technology can synergize cost, process time, quality, and complexity. Large-sized parts applied with expensive materials, like stiffened panels, wing ribs, gas turbines, and pipelines, require an innovative manufacturing process to reduce cost and time. The long-term objective of this research proposal is to achieve the necessary technologies to build a robotic metal hybrid additive and subtractive manufacturing system. The proposed short-term objectives of this research are to understand the dynamics of the system and to improve upon the manipulators' current structural challenges. The robotic metal hybrid manufacturing system itself is novel. The automatic identification methods, the mode coupling effects analysis, and the self-adjustable vibration reduction device are also novel. This proposal's outcomes will be an automatic identification module, stability maps to increase process efficiency, and a self-tunable device. The technological outcomes achieved through the proposed program will enhance Canada's manufacturing technology, serve as catalysts for other novel applications and developments, and promote technology transfer to industry partners. This research is essential for the interdisciplinary training of highly-qualified personnel, who will learn about system design, dynamics, mechatronics, vibration, manufacturing, simulation, and control.