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5 Axis Hybrid Manufacturing Model and Simulation

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The Hybrid Manufacturing is the blend of subtractive and additive manufacturing processes. Additive manufacturing processes have seen nowadays as an upward trend in complex and structurally sound industrial applications. At the same time, there is still an open ground in modeling and simulation techniques when applied to these processes. There are many fabrication processes in modern manufacturing, but current modeling and simulation tools only simulate a few unit processes based on different geometry models. To overcome the problem between different models, this paper studies various in-process geometry models together with their working systems for traditional manufacturing processes. Novel hybrid 5 axis multiple machining, 5 axis laser cladding, and layered manufacturing processes are presented to identify critical issues. Working towards a vision of pervasive modeling and simulation, a unified deformable in-process geometry model and simulation for 5 axis multiple machining, 5 axis laser cladding, and layered manufacturing simulations is developed and discussed.

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5 Axis Hybrid Manufacturing Model and Simulation

  1. 1. Unified Model and Simulation of Hybrid Manufacturing Processes Mr. Liu Peiling Principal Research Engineer Singapore Institute of Manufacturing Technology 71 Nanyang Drive, Singapore 638075 Tel: 65-67938356 Mobile: 65-90123598 Fax: 65-67916377 plliu@simtech.a-star.edu.sg http://simtech.a-star.edu.sg
  2. 2. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 2 Hybrid Manufacturing The Hybrid Manufacturing is the blend of subtractive and additive manufacturing processes. Additive manufacturing processes have seen nowadays as an upward trend in complex and structurally sound industrial applications. At the same time, there is still an open ground in modelling and simulation techniques when applied to these processes.
  3. 3. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 3 Commercial Solutions A quick reuse of conventional material removal model without an realistic additive features Simplified deposition track road shape Mike Nicholson, Sales & Marketing Director of MachineWorks says, "We have always been able to deliver material addition as well as material removal but recently we have seen the demand for additive simulation rocketing".
  4. 4. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 4 Our solutions: A unified hybrid manufacturing model Multiple materials and surface textures  Composite, surface painting, marking, …… Multiple processes  3-5 axis machining  2.5 axis 3D printing, such as SLA, SLS, LOM,……  3-5 axis cladding, welding……
  5. 5. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 5 5 Axis Cladding Nozzle Perpendicular to Deposition
  6. 6. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 6 Deposition Track Road Shape Melting Pot Simulation
  7. 7. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 7 Start 5 Axis Machining
  8. 8. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 8 5 Axis Flank Milling
  9. 9. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 9 Clear Surface Details
  10. 10. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 10 Multiple Material Deposition 10
  11. 11. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 11
  12. 12. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 12
  13. 13. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 13
  14. 14. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 14 Test Case Vase
  15. 15. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 15 5 Axis Cladding on Blade Tip Import a scanned blade model in STL format Automatic generate 3 axis milling, 3-5 axis cladding and 5 axis machining toolpath Simulate 3 axis milling to remove the tip Simulate 3-5 axis cladding to build the tip Simulate 5 axis machining to clean the remaining stock
  16. 16. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 16 Cut off Damaged Blade Tip
  17. 17. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 17 3 Axis Cladding on Blade Tip
  18. 18. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 18 5 Axis Cladding on Blade
  19. 19. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 19 5 Axis Milling to Clear Remains
  20. 20. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 20 5 Axis Milling to Clear Remains
  21. 21. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 21 Finishing with 5 Axis Milling
  22. 22. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 22 5 Axis Cladding on Blade Tip
  23. 23. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 23 Higher Precision Finishing
  24. 24. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 24
  25. 25. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 25
  26. 26. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 26
  27. 27. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 27
  28. 28. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 28
  29. 29. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 29
  30. 30. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 30
  31. 31. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 31
  32. 32. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 32
  33. 33. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 33
  34. 34. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 34 5 Axis Machining Simulation
  35. 35. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 35 Start to Cut
  36. 36. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 36 Roughing within 3 Minutes
  37. 37. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 37 Toolpath and in Process Model
  38. 38. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 38 Finishing with Multiple Operations
  39. 39. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 39 Zoom In Details
  40. 40. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 40 See from Another Angle
  41. 41. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 41 Industry Strength Application
  42. 42. Confidential © 2015 All rights reserved Singapore Institute of Manufacturing Technology Slide 42 Summary Unified hybrid manufacturing model Multiple materials and processes simulation Cladding track road shape Ten times faster than NX 3D simulation  Voxel model based simulation  Swept volume speeding algorithm  Toolpath modeling and simulation Automatic generation of 5 axis toolpath

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