Innovative Process Planning Strategies for Bead Deposition Based Additive Manufacturing Processes

添加制造(AM)方法由无需工具的工艺组成，该工艺可以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)零件和组件。AM工艺正变得越来越普遍；然而，支持一般系统配置(即机床或机器人单元)基于珠粒的沉积AM工艺的设计和制造活动的工艺规划解决方案有限，并且虚拟仿真工具有限。机器人和通用机床制造商正在开发设备，以增加制造大型、多材料部件，但没有材料-工艺-部件库，也没有现成的全面建造策略。从本质上讲，正在开发使用AM方法制造部件的专用系统，但很少有制造商知道如何有效地使用它们。拟议的研究计划将侧重于了解工艺特征，以扩大和优化可以支持各种AM平台并与加工平台集成的“工艺建模、规划和验证”机会。与研究相辅相成的是为工业界开发设计工具，使新的制造机会得以实现。目标应用是用于添加制造元素的材料挤压、线弧和激光熔覆。本研究将研究混合制造，即材料添加和减法(机械加工)操作相结合以创建最终的工艺计划。由于在材料沉积和固化时会发生激进的加热和冷却循环，因此工艺规划解决方案应考虑这些热特性。众所周知，由于热流的变化，铸造和焊接过程中会发生变形--这种现象需要在AM工艺中进行探索，并且需要开发工艺规划解决方案来解决这些问题。通过创建新的刀具路径选项，以及独特的平面和非平面行进路径策略，将开发挑战恒定胎圈宽度和2D分层范例的技术。这将既解决与AM珠粒沉积工艺相关的挑战，又利用与AM珠粒沉积工艺相关的机遇‘混合制造，将材料沉积成近净形状，然后进行机械加工，为工艺规划策略引入了一个新的维度。这一研究领域也需要深入探索，因为机床公司正在开发能够实现这一功能的设备，但没有知识库来利用这些设备的能力。据预测，到2025年，AM对全球的影响将超过5000亿美元。这项研究将有助于开发HQP，并为从事高级AM活动的加拿大人提供相关解决方案。

Additive Manufacturing (AM) methods consist of tool-less processes that can produce complex three dimensional (3D) parts and assemblies by successively layering two dimensional (2D) cross-sections of material. AM processes are becoming more common; however, there are limited process planning solutions to support design and manufacturing activities for general system configuration' (i.e. machine tool or robot cell) bead based deposition AM processes, and there are limited virtual simulation tools. Robotic and general machine tool manufacturers are developing equipment to additively manufacture large, multi-material components, but there are no material-process-component libraries and no comprehensive building strategies readily available. Essentially, specialty systems are being developed to fabricate components using AM approaches, but very few manufacturers know how to effectively use them. The proposed research program will focus on understanding process characteristics to expand and optimize 'Process Modelling, Planning and Verification' opportunities, which can support a variety of AM platforms, and integrate with machining platforms. Complementing the research is the development of design tools for the industrial community that will enable new manufacturing opportunities to be realized. The target applications are material extrusion, wire arc, and laser cladding for the additive manufacturing element. Hybrid manufacturing, where material addition and subtraction (machining) operations are combined to create the final process plan, will be investigated in this researchAs aggressive heating and cooling cycles occur when materials are being deposited and solidified, process planning solutions should consider these thermal characteristics. 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 process planning solution alternatives to manage these issues need to be developed. Techniques to challenge the constant bead width' and the 2D layering' paradigms by creating new tool path options, and unique planar and non-planar travel path strategies will be developed. This will address both the challenges and leverage the opportunities associated with AM bead deposition processes Hybrid manufacturing, where material is deposited as a near net shape', and then machined, introduces a new dimension for process planning strategies. This research area also needs to be explored in-depth, as machine tool companies are developing equipment capable of this functionality, but there is no knowledge base to leverage these equipments' capabilities.It is predicted that the global impact for AM by 2025 will reach over $500 billion. This research will help develop HQP, and provide relevant solutions for Canadians engaged in advanced AM activities.