Single-Machine Forming and Machining With Spatial Coherence
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Solution Overview
Problem
Current manufacturing processes require separate machines for different operations such as forging, machining, and 3D printing, leading to increased labor and equipment costs, errors due to loss of spatial coherence, and difficulties in maintaining precise alignment, which can result in costly rework or the inability to produce certain parts.
Innovation Solution
A system and method that integrates multiple operations, including forming, subtractive, and additive manufacturing, within a single machine, maintaining spatial, temporal, and environmental coherence to perform a combination of heating, cooling, forming, subtractive, and additive operations in a spatially coherent manner, allowing for the integration of transformative and inspecting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple operations (forming, machining, additive manufacturing) are performed in separate machines, then each operation can be performed with dedicated equipment, but labor and equipment costs increase, and spatial alignment errors occur due to part repositioning
Solution Approach 1:
The patent combines multiple manufacturing operations (forming, machining, additive manufacturing, heat treatment) into a single integrated machine system. This merging eliminates the need to transfer parts between separate machines, thereby maintaining spatial coherence and alignment precision throughout the manufacturing process while reducing the total number of machines required
Solution Approach 2:
The integrated machine system is designed to perform multiple different manufacturing operations within a single platform. The system can switch between forming operations, subtractive machining, additive manufacturing, and heat treatment processes, making one machine universal enough to replace multiple specialized machines while maintaining consistent spatial references
2Productivity
If parts are moved between machines for different operations, then specialized equipment can be used for each operation, but additional labor costs are incurred and time is lost due to transport and repositioning
Solution Approach 1:
The integrated machine system enables continuous manufacturing operations without interruption for part transfer. The system can perform forming, machining, additive manufacturing, and heat treatment in sequence within the same machine, eliminating idle time associated with moving parts between machines and maintaining continuous productive action throughout the manufacturing process
3Manufacturing precision
If thermal energy operations (heating, cooling) are performed in separate machines, then dedicated thermal processing equipment can be used, but parts must be cooled before moving to another machine, causing dimensional changes and alignment issues
Solution Approach 1:
The patent integrates thermal processing capabilities (heating and cooling operations) directly into the manufacturing machine system. This allows thermal operations to be performed immediately after or during manufacturing operations without removing the part from the machine, eliminating the cooling period that causes dimensional changes and maintaining spatial coherence throughout the process
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 delays, costs, and waste by enabling the performance of multiple operations in a single machine, improving precision and reducing the likelihood of errors, allowing for the production of parts that would be impossible to manufacture separately, such as high-value alloys with complex geometries.
Implementation Method 1
heating elements configured to heat the workpiece
Implementation Method 2
cooling elements configured to cool the workpiece
Data Source
AI summary
A spatially coherent machine for manufacturing comprises, in one example, a workpiece holder configured to secure a workpiece, a toolholder with at least one axis of motion control configured to perform a subtractive machining operation on the workpiece using a machining tool, a heating element configured to perform a heating operation on the workpiece, and a forming element configured to perform a forming operation in which force is applied to the workpiece in an amount that causes plastic deformation of the workpiece material. The workpiece holder secures the workpiece during the heating, forming, and subtractive operations such that the forming and subtractive operations are performed in a spatially coherent manner.