A robotic metal hybrid additive and subtractive manufacturing system

机器人金属混合增材减材制造系统

• 批准号: RGPIN-2020-04205
• 负责人: Lee, Jihyun
• 金额: $ 1.97万
• 依托单位: University of Calgary
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=759766
• 关键词: robotic; metal; hybrid; additive; subtractive

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.

对使用尖端金属材料在航空航天，汽车和能源部门中开发和修复大型复杂结构的需求不断增长，因此需要开发低成本的制造工艺。层压材料以创建所需工件形状的添加剂制造令人着迷，因为它可以应对各种几何挑战，例如内部和悬垂功能以及具有较高“购买与仿制”比率的零件。但是，当前，添加剂的制造能够产生低表面饰面，不均匀沉积的层，高材料成本，较长的过程时间和限制尺寸的组件。 该研究计划向最先进的系统提出了建议，该系统可以通过在添加剂过程中协作操纵器来同时削减不平衡层，以克服这些挑战。混合制造将常规减法制造工艺与添加剂过程结合在一起，使我们能够使用相对便宜的实心材料而不是昂贵的粉末材料。这种变化可以减少生产时间，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。这些过程的平台由操纵器组成，可以是节省成本，配置且可忽略的和多维的替代方案。因此，将机器人技术，减法过程和添加过程结合在一起，可以协同成本，过程时间，质量和复杂性。大型零件涂有昂贵的材料，例如僵硬的面板，翅膀肋骨，燃气轮机和管道，需要创新的制造工艺，以降低成本和时间。该研究建议的长期目标是实现建立机器人金属杂交和减法制造系统的必要技术。这项研究的拟议短期目标是了解系统的动态，并改善机械师当前的结构挑战。机器人金属混合制造系统本身是新颖的。自动识别方法，模式耦合效应分析和可自调节的振动还原装置也是新颖的。该提案的结果将是一个自动识别模块，提高过程效率的稳定图以及一个自动启动设备。 通过拟议计划实现的技术成果将增强加拿大的制造技术，作为其他新型应用和开发的催化剂，并促进技术转移到行业合作伙伴。这项研究对于对高度合格人员的跨学科培训至关重要，他们将了解系统设计，动态，机电一体化，振动，制造，模拟和控制。