A robotic metal hybrid additive and subtractive manufacturing system

在航空航天、汽车和能源领域，对使用尖端金属材料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。层压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，增材制造产生低表面光洁度、不均匀沉积层、高材料成本、长加工时间和受限尺寸的部件。 该研究计划提出了一种最先进的系统，该系统可以在增材过程中通过协作机械手同时切割不均匀的层，以克服这些挑战。混合制造将传统的减材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实心线材材料，而不是昂贵的粉末材料。通过在短时间内快速切割层压材料的不平整表面，这一变更缩短了生产周期并提高了表面质量。由机械手组成的这些过程的平台可以是节省成本、配置灵活和多维的替代方案。因此，将机器人技术、减材工艺和增材工艺结合到一项技术中可以协同降低成本、工艺时间、质量和复杂性。采用昂贵材料的大型零件，如加强板、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，以建立机器人金属混合增材减材制造系统。这项研究的短期目标是了解系统的动力学，并改善机械手目前的结构挑战。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整减振装置等也是新颖的。该提案的成果将是一个自动识别模块，稳定性地图，以提高过程效率，和一个自我可调的设备。 通过拟议计划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，并促进向行业合作伙伴的技术转让。这项研究对于高素质人才的跨学科培训至关重要，他们将学习系统设计，动力学，机电一体化，振动，制造，仿真和控制。

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.