Bonded Precision Inserts for AM Tolerance Absorption
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Solution Overview
Problem
Additive manufacturing (AM) systems face challenges in achieving consistent dimensional accuracy and stability, which can be a limitation for forming certain components, while traditional non-AM methods excel in these aspects, but lack the geometric complexity and efficiency of AM.
Innovation Solution
A method is developed to combine AM and non-AM components by using bonding agents in a bond gap to absorb dimensional variances, allowing for precise alignment and bonding of AM and non-AM components, leveraging robots for automated assembly and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additive manufacturing is used to create geometrically complex components, then geometric complexity and manufacturing efficiency are improved, but dimensional accuracy and dimensional stability deteriorate
Solution Approach 1:
The component is divided into two separate parts: an additively manufactured portion providing geometric complexity and a traditionally manufactured portion providing dimensional accuracy. These segments are then bonded together to form a hybrid component that leverages the strengths of both manufacturing methods.
Solution Approach 2:
The invention creates a composite structure by bonding components made from different manufacturing processes. The hybrid component combines AM materials (providing complex geometry) with traditionally manufactured materials (providing dimensional stability), effectively creating a composite solution at the component level.
2Productivity
If additive manufacturing is used to produce components, then manufacturing efficiency and design freedom are improved, but dimensional stability deteriorates
Solution Approach 1:
The component is segmented into regions manufactured by different processes. The AM portion handles complex, low-volume production requirements for efficiency and design freedom, while the traditionally manufactured portion ensures dimensional stability where required.
Solution Approach 2:
Different manufacturing qualities are applied to different regions of the component. The AM portion provides design freedom and efficiency where complex geometry is needed, while the traditionally manufactured portion provides dimensional stability where precision is critical.
3Manufacturing precision
If a bond gap is introduced to absorb dimensional variances, then alignment precision is improved, but structural integrity may worsen
Solution Approach 1:
The bond gap acts as an intermediary element between the two components, absorbing dimensional variances and preventing stress concentration. This mediator allows for thermal expansion differences and manufacturing tolerances while maintaining the structural integrity of the assembled component.
Solution Approach 2:
The bond gap changes the physical parameters of the assembly by introducing a compliant interface. This parameter change allows for dimensional adjustments and stress distribution, maintaining structural integrity despite the presence of the gap.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the creation of robust, accurately aligned vehicle components that combine the geometric complexity of AM with the dimensional stability and cost-effectiveness of non-AM methods, addressing the limitations of both technologies.
Implementation Method 1
an adhesive in the bond gap bonds the AM component bonding portion and the machined component bonding portion
Data Source
AI summary
A combination component with an additively manufactured (AM) component and a non-AM manufactured component and method of producing a combination component is described. The method includes joining the AM component with a non-AM component. The method further includes retaining the AM component, wherein the AM component has an AM component bonding portion and retaining the non-AM component, wherein the non-AM component has a non-AM component bonding portion that is configured to be bonded with the AM component bonding portion with a bond gap therebetween for absorbing dimensional variances in the AM component or the non-AM component.