Tip Structure Alignment Using an Engraved Reference Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In hybrid additive manufacturing, accurately aligning a manufacturing setup with the top surface of a pre-existing part for powder-bed-based deposition of a tip structure is challenging due to tolerance stacking effects and requires complex machining operations, leading to insufficient accuracy.
Innovation Solution
A method involving an aligning plate that is engraved with the top contour of the part using an energy beam, allowing for precise alignment of the part's surface with the engraved contour, enabling accurate positional calibration and simplifying the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical recognition systems are used to align the manufacturing setup with the pre-existing part, then alignment can be performed, but accuracy is insufficient due to tolerance stacking effects and complex machining operations are required
Solution Approach 1:
The method performs preliminary alignment by engraving the contour of the pre-existing part onto the aligning plate before the actual additive manufacturing process. This preliminary contour transfer enables accurate positioning without requiring complex post-alignment operations or dealing with tolerance stacking effects during manufacturing.
Solution Approach 2:
The aligning plate creates a precise copy of the part's contour through energy beam engraving. This copied contour serves as a reference template that simplifies subsequent alignment operations and eliminates the need for complex optical recognition systems and multiple machining operations.
2Manufacturing precision
If conventional alignment methods with mounting dowels are used, then the manufacturing setup can be calibrated, but accuracy is reduced due to tolerance stacking effects and multiple machining operations are required
Solution Approach 1:
The method extracts and transfers only the essential contour information of the pre-existing part onto the aligning plate, eliminating the need for complex mounting dowel systems and multiple alignment operations. This extraction of critical geometric information simplifies the entire calibration process while maintaining high precision.
Solution Approach 2:
The invention replaces the mechanical alignment system based on mounting dowels and multiple machining operations with an energy beam-based contour engraving system. This substitution eliminates mechanical tolerance stacking effects and simplifies the alignment process to a single contour transfer operation.
3Measurement precision
If the aligning plate method is used, then alignment accuracy is improved and the process is simplified, but an additional aligning plate component is introduced
Solution Approach 1:
The aligning plate serves multiple functions: it acts as a support surface for the pre-existing part, a template for contour transfer, and a reference for positioning the additive manufacturing build platform. This multi-functionality justifies the additional component by eliminating the need for multiple separate alignment devices and complex optical systems.
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 method achieves high alignment accuracy and flexibility, facilitating repeatable high-quality refurbishment or completion of parts by adapting the geometric settings of the laser tooling to the pre-existing part, suitable for various physical geometries and service applications like turbo machine components.
Implementation Method 1
A method of selective laser melting is described in EP 2 601 006 B1, for example
Implementation Method 2
The setup can be selective laser melting setup or electron beam melting setup, for example
Implementation Method 3
engraving a mating or top contour or cross section of the part onto or in the aligning plate with an energy beam of the setup, such as a laser or electron beam
Implementation Method 4
engraving a mating or top contour or cross section of the part onto or in the aligning plate with an energy beam of the setup, such as a laser or electron beam
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A method for additively manufacturing a tip structure (G) on a pre-existing part (H) is presented, the method comprising: - a) placing the part (H) in a build space (30) of a beam- assisted additive manufacturing setup (100) and below a transparent aligning plate (E), - b) engraving a top contour (H) of the part (F) onto the aligning plate (E) with an energy beam (101) of the setup (100), - c) aligning a top surface (11) of the part (F) such that the top surface coincides with the engraved contour (H), - d) removing the aligning plate (E) from the setup (100), and - e) additively manufacturing the tip structure (G) according to a predefined geometry on the top surface (11).