3D Shape Processing With Enlarged Build Surfaces for Machining Allowance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods combining cutting work and additive manufacturing face challenges in ensuring sufficient machining allowance, particularly for overhang shapes, leading to insufficient volume and tapered shapes due to the properties of additive manufacturing.
Innovation Solution
A three-dimensional shape processing method that forms a target surface larger than the shape dimension for additive manufacturing, followed by cutting work to ensure machining allowances, allowing for the completion of the three-dimensional shape with improved productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is performed directly on the target surface without enlarging it, then the shaping process is simpler, but the machining allowance is insufficient leading to volume deficiency and tapered shapes
Solution Approach 1:
The target surface is enlarged in advance before additive manufacturing is performed. This preliminary enlargement creates sufficient machining allowance that will be removed later, preventing volume deficiency and tapered shapes in the final product while maintaining process simplicity
2Manufacturing precision
If the target surface is enlarged to ensure machining allowance, then shape accuracy is improved, but the processing complexity increases
Solution Approach 1:
The enlargement of the target surface is performed as a preliminary action before additive manufacturing. This approach simplifies the overall process by establishing the necessary machining allowance upfront, avoiding the need for complex real-time adjustments or multiple processing stages
3Productivity
If conventional cutting work and additive manufacturing are combined without surface enlargement, then productivity is higher, but machining allowance is insufficient
Solution Approach 1:
The target surface enlargement is performed as a single preliminary action before additive manufacturing, rather than requiring multiple iterative adjustments during processing. This approach ensures sufficient machining allowance is available from the start, enabling efficient one-pass additive manufacturing without compromising productivity
Data Source
AI summary
A three-dimensional shape processing method processes a workpiece into a predetermined three-dimensional shape by cutting work and additive manufacturing. The method includes forming a target surface for the additive manufacturing to be larger than a shape dimension of the three-dimensional shape, performing the additive manufacturing on the target surface that has been largely formed, and performing the cutting work on a region where the additive manufacturing has been performed to complete the three-dimensional shape.