Hybrid Additive-Subtractive Toolpaths for Vibration and Distortion
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Solution Overview
Problem
Current hybrid additive and subtractive manufacturing systems face challenges in maintaining stability and accuracy during the production of complex structures, particularly in high-temperature environments, due to excessive vibration and material distortion, which can lead to tool damage and part inaccuracies.
Innovation Solution
The implementation of a hybrid manufacturing process that combines additive and subtractive manufacturing stages, utilizing numerical simulation to adjust material amounts and toolpaths, and incorporating blade roots as integral parts of the hub to enhance structural integrity and reduce thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hybrid additive and subtractive manufacturing is used to produce complex structures, then manufacturing flexibility and structural integrity are improved, but vibration and material distortion increase leading to tool damage and part inaccuracies
Solution Approach 1:
The patent applies preliminary action by performing numerical simulations before actual manufacturing to predict thermal effects and material distortion. The simulation results are used to pre-adjust toolpaths and material deposition parameters, preventing accuracy issues before they occur during hybrid manufacturing operations.
Solution Approach 2:
The system implements feedback through iterative simulation-manufacturing cycles. Thermal effects and material behavior are simulated, results are analyzed, and manufacturing parameters are adjusted accordingly. This closed-loop approach continuously improves part accuracy while maintaining structural integrity during hybrid manufacturing.
2Adaptability or versatility
If additive manufacturing is used to build complex geometries, then design freedom and material efficiency are improved, but thermal effects cause material distortion and deviation from target geometry
Solution Approach 1:
The patent performs preliminary numerical simulations to predict thermal distortion patterns before additive manufacturing. Based on simulation results, compensation strategies are pre-planned into the toolpaths and deposition parameters, allowing complex geometries to be built with maintained geometric accuracy despite thermal effects.
Solution Approach 2:
The system dynamically adjusts manufacturing parameters based on simulated thermal predictions. Deposition rates, laser power, and cooling parameters are modified in response to predicted thermal effects, enabling complex geometries to be manufactured with controlled distortion while preserving design freedom.
3Ease of manufacture
If conventional tools are used in hybrid manufacturing, then tool costs are reduced, but tool life decreases due to excessive vibration
Solution Approach 1:
The patent uses preliminary simulations to predict vibration patterns before manufacturing. Toolpaths are pre-optimized to minimize vibration excitation, allowing conventional tools to be used effectively. This approach extends tool life by preventing excessive vibration while maintaining the cost advantage of using conventional tools in hybrid manufacturing.
4Manufacturing precision
If material is removed in subtractive manufacturing stages, then blending between additive stages is improved, but excessive vibration occurs leading to tool damage
Solution Approach 1:
The patent performs preliminary simulations to predict vibration and thermal effects before subtractive manufacturing operations. Based on these predictions, material removal rates and toolpaths are pre-optimized to achieve adequate blending between additive stages while keeping vibration levels below damage thresholds for cutting tools.
Solution Approach 2:
The system dynamically adjusts subtractive manufacturing parameters based on simulated predictions. Cutting depths, feed rates, and toolpaths are modified to balance blending quality with vibration control, preventing tool damage while maintaining adequate material removal for effective blending between additive manufacturing stages.
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 reduces material usage, manufacturing time, and tool costs by allowing the use of conventional tools, while improving the accuracy and stability of complex structures, particularly in high-temperature applications, by minimizing vibration and distortion.
Implementation Method 1
additive manufacturing, also known as solid free form fabrication or 3D printing, refers to any manufacturing process where 3D parts are built up from raw material (generally powders, liquids, suspensions, or molten solids)
Implementation Method 2
3D parts are built up from raw material (generally powders, liquids, suspensions, or molten solids) in a series of two-dimensional tiers or cross-sections
Implementation Method 3
subtractive manufacturing refers to any manufacturing process where 3D parts are created from stock material (generally a 'blank' or 'workpiece' that is larger than the 3D part) by cutting away portions of the stock material
Implementation Method 4
hybrid manufacturing systems have been developed, where additive and subtractive manufacturing are combined, such as a CNC machine that combines laser metal deposition with high-precision 5-axes adaptive milling
Implementation Method 5
the simulating includes simulating thermal effects of adding and removing the material in the first and second stages
Implementation Method 6
the simulating includes simulating vibration experienced during at least the removing of the second material
Implementation Method 7
the simulating includes simulating thermal effects of adding and removing the material in the first and second stages
Data Source
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AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design and manufacture of physical structures using hybrid additive and subtractive manufacturing include, in one aspect, a method including: obtaining data for 3D geometry of a part; simulating at least a portion of a manufacturing process that includes adding first material in a first stage and removing second material in a second, subsequent stage, where the second material includes a portion of the first material, removing the second material includes blending between the material added in the first and second stages, and thermal effects of adding and removing the material in the first and second stages is simulated; and adjusting an amount of the portion based on results of the simulating to prevent deviation of the part from the three dimensional geometry that results in not enough material being available for the blending.