CNC Spindle Attachment for Continuous Wire Deposition
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Solution Overview
Problem
Current additive manufacturing techniques, particularly in solid state additive manufacturing and friction surfacing additive manufacturing, face challenges in efficiently depositing materials without melting, which limits the control over microstructure gradients and interfacial bond strength in complex designs.
Innovation Solution
A spindle attachment system with a rotating assembly and wire feeder for CNC machines, allowing continuous supply of deposition material to an application tip, where friction generates heat to plasticize the material without melting, enabling controlled deposition of layers with adjustable rotational speed, traverse speed, and applied load for precise bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If friction and pressure are applied to heat deposition material to near melting point, then the deposition material plasticizes and can be applied to substrate, but the material must not melt which limits control over microstructure gradients
Solution Approach 1:
The system dynamically adjusts multiple parameters including rotational speed of the spindle, traverse speed of the tool, and applied load to precisely control the friction-generated heat. By changing these parameters during the deposition process, the system maintains the deposition material at optimal plasticization temperature without melting, thereby achieving precise control over microstructure gradients in the deposited layers
Solution Approach 2:
The invention employs a dynamic control system that continuously monitors and adjusts the friction surfacing parameters during operation. The rotational speed, feed rate, and contact pressure are dynamically modified based on real-time process conditions, enabling precise thermal management that prevents material melting while maintaining plasticization for controlled microstructure development
2Adaptability or versatility
If multiple tool attachments are used to machine a single workpiece, then both additive and subtractive processes can be performed, but the machine complexity increases
Solution Approach 1:
The spindle assembly is designed as a universal tool that can perform both additive manufacturing (friction surfacing deposition) and subtractive machining operations. The same spindle, when equipped with appropriate tool attachments, can deposit material layers and subsequently machine them, eliminating the need for separate dedicated machines and reducing overall system complexity while maintaining full functional versatility
3Productivity
If wire is fed continuously from material supply to application tip, then deposition process efficiency improves, but the system complexity increases
Solution Approach 1:
The wire feeding mechanism is integrated directly into the spindle assembly, merging the material supply function with the rotational tool. The wire feeder is positioned within the spindle housing and feeds wire through the rotating assembly to the application tip, combining what would traditionally be separate subsystems into a single unified structure, thereby improving deposition efficiency without proportionally increasing system complexity
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 solution enables defect-free parts with high interfacial shear strength and controlled microstructure gradients, facilitating the production of complex designs with enhanced mechanical hardness and reducing the need for multiple machines by allowing both additive and subtractive processes on a single CNC machine.
Implementation Method 1
friction and pressure between the deposition material and the substrate cause the deposition material to heat to near its melting point
Implementation Method 2
rotating the spindle relative to the substrate to generate frictional heat where the wire contacts the substrate
Implementation Method 3
cause the deposition material to heat to near its melting point, thereby causing the deposition material to plasticize but not melt
Data Source
AI summary
A rotating tool system attachment on the spindle of a computer numerical control (“CNC”) machine includes a rotating assembly mounted on a static assembly. The rotating assembly provides a continuous supply of a wire material for deposition on a substrate during an additive manufacturing process. The rotating assembly includes a material supply housing a feedstock of wire mounted on a rotating spindle and a wire feeder configured to draw the wire from the wire supply and provide the wire for application during the additive manufacturing process. The tool system can be attached to the spindle of CNC machine to provide additive manufacturing capabilities to the CNC machine.