5 axis 3 d hybrid manufacturing automation 五轴三维增减材复合制造自动化

5 Axis 3D Hybrid Manufacturing Automation
五轴三维增减材复合制造自动化
unified modeling, simulation, verification, and optimization
统一建模，仿真，验证和优化
Mr. Liu Peiling 刘蓓龄
Principal Research Engineer 首席研究工程师
Singapore Institute of Manufacturing Technology 新加坡制造技术研究院
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

Confidential © 2016 All rights reserved
Singapore Institute of Manufacturing Technology Slide 2
Agenda 演讲纲领
Yesterday 三维模具设计与数控加工仿真
 3D mold design and machining, NC verification
Today 基于仿真的设计
 Simulation based design optimization
 2.5 axis 3D additive manufacturing
Tomorrow五轴三维增减材复合制造
 5 axis 3D hybrid manufacturing
 So, where does it leave us?未来道路向何方？

昨天历史回顾 Yesterday
3D Injection Mold Design

三维模具设计系统的开发
3D Mold Design System Development 1995 -1998
IMOLD and QuickMold projects to create a
world first 3D mold design platform:
 Develop & market IMOLD product
 主席倪亦靖（Andrew Nee）博士，新加坡国立大学教授，
国际生产工程科学院CIRP首位华人主席
 Spun off Manusoft Technologies Pte Ltd
 QuickMold merged with UGS MoldWizard
 QuickSeeNC was developed for NC verification

QuickSeeNC 1996 QuickCNC 2014
三分钟全自动验证数控程序
Full automatic verification in three minutes:
automatic generate raw material block, one click open all NC files with cutters,
automatic verification, instant warning…
Low cost PC
Customizable
No-history based
 Faster for HSM
100% accurate
Full automatic
Machine code
simulation

操作培训仿真 Virtual CNC Operation Training
-Mr. Lee Yi Shyan was GOH for both VCNCLab and QuickCNC lanuch events, and
praised them three times. “if we are not to do this, CNC machine tool will be in
museum of Singapore.”
-Mr. Lim Hng Kiang praised them as “a new technology platform” that will
“equip our precision engineering enterprises with niche capabilities”
www.engineeringchallenges.org

今天的技术 Today

数控优化 Using NC Optimization…
High Speed Machining
慢速度 Slow the feed rate for hostile
conditions
大深度Potentially employ greater
axial depth
积极的进给率 Maintain aggressive
feed rates for high speed “friendly”
cuts
More efficient material removal
Fewer passes = less machining time
Fewer cycles = less wear on machine
Efficiency 高效加工

数控代码仿真与优化
NC Code Simulation and Optimization
Reverse post-processor
Verification/Simulation
Dimensional Analysis
Optimization
CAD CAM post-
processor
machining
part design
tool path
generation
production
Reverse post-processor
Verification/Simulation
Dimensional Analysis
Optimization
validated ISOISOAPT/CL3D
Design Office Manufacturing Engineering Department Workshop

基于仿真的设计
Simulation based Design
MATRIX
a simulated world

挑战 Challenge: 取代三周试制
Replace Three Weeks Trial Fabrication

VaneAdviser 叶片顾问
Core slot display
Pull out path
Vane
model
Top face
Core slot
gap
Simulation
Dialog
Posture info
Design Dialog

13

Tomorrow: Lots of Rabbits?
明天骄兔遍地？

现有増材制造技术不足之处
増材制造仍然存在表面质量相对较差、尺寸精度较低
、零件材料致密性较低等缺点，加工出来的零件难以
直接用于实际应用中，在通过增材制造方法完成零件
成型后往往需要利用车削、铣削、磨削等减材制造方
法进行减材制造，以达到零件所需的表面质量与尺寸
精度。然而，对于结构复杂的零件表面，常因工件结
构的干涉而无法实现复杂表面的减材制造，并且，增
材制造与减材制造分别进行，需要重新装夹、定位，
这样会影响加工精度与加工效率。因此，单一的増材
制造或者单一的减材制造均无法胜任结构复杂、表面
质量要求高、尺寸精度要求高的零件的快速高效生产
。

What is Hybrid Manufacturing ?
什么是增减材复合型制造？
Additive 增
+
Machining 减
IN ONE SYSTEM
Metal Laser Sintering
一个系统
金属激光烧结

No Splitting: Create in One 无分体
Eliminating assembly and adjustment stages and making it possible to produce with no
dimensional errors that may be caused by conventional assembly processes.

Why 5 Axis?
为什么五轴？复杂零件！
Metal Laser Sintering is 2.5 axis that was
invented for mould die insert, which you
can see all surfaces from top viewpoint
For complex parts, such as turbine, drill bit,
valves, which are traditional produced with
a 5 axis machine, you need 5 axis

统一建模，仿真，验证和优化
为了有效解决当前増材制造设备制造出
的零件难以直接用于实际生产的问题，
提供了一种根据CAD模型数据增减材复合
制造统一建模，仿真，验证和优化，进
行増材制造和减材制造的交替，进行复
杂曲面零件的一次性成型制造，无需二
次加工，可以有效提高复杂零件的加工
效率与成型精度。

Drill Bit CAD Model and Part
钻头CAD模型和部件
DMG MORI Singapore

Turbine Housing Model & Part
涡轮壳模型与配件
DMG MORI Singapore

Conformal Cooling Model & Part
随形冷却模型与配件
DMG MORI Singapore

Valve Model in Siemens NX
西门子NX 瓣膜阀门模型

Valve NX CAM ToolPaths
阀门NX CAM刀具路径
DMG MORI Singapore

Valve NX CAM ToolPaths 2
阀门NX CAM刀具路径
DMG MORI Singapore

DMG MORI Singapore

5 Axis Hybrid Manufacturing
五轴三维增减材复合制造研究
still an open ground for research and development
Deposition toolpath planning and generation.
Deposition track road shape bead geometry. 沉积
轨道规划和生成，轨迹焊道形状。
Additive Boolean operation 加性布尔运算
Machining remaining stock 剩余加工存量
5 axis machining toolpath generation 刀路生成
5 axis machining Boolean operation 布尔运算
Deformation predication 变形预测

Commercial Solutions
旧的传统解决方案
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".

MachineWorks Hybrid Manufacturing

IMS Hybrid Manufacturing Simulation

ModuleWorks Additive Manufacturing

Proposed at ASME Congress
美国制造工程师2005大会提议
A unified hybrid manufacturing model
统一的增减材混合制造模型
Multiple materials and surface textures
多种材料和表面纹理
 Composite, surface painting, marking, ……
Multiple processes多进程
 3-5 axis machining三至五轴加工
 2.5 axis 3D printing, such as SLA, SLS, 两轴半
 3-5 axis cladding, welding……三至五轴熔覆

LM Toolpath ASME 2005
层制造沉积路径

One Layer LM ASME 2005
一层沉积路径

LM Simulation ASME 2005
层制造仿真

LM tool path
Generate road
shape
Voxelization of
road shape
Boolean addition
Visualization &
analysis
Voxel Model
NC tool path
Generate Swept
volume
Voxelization of
swept volume
Boolean
subtraction
Visualization &
analysis
Unified Geometrical Model 2005
统一的几何模型
X
Z
Y

3D Additive Manufacturing
三维加性増材制造
3D Additive Manufacturing Software
3D Object Models in STL
Automatic support design
Automatic layout optimization
Slicing functions
G code for Additive
Manufacturing
Manual
design
+
3D printing
rules &
regularities
3D printing rules and regularities will be
programmed into the software

5 Axis Hybrid Manufacturing
五轴增减材复合制造
5 Axis 3D Hybrid Manufacturing Software
3D Object Models in STL
5 axis toolpath planning
5 axis deposition generation
5 axis deposition simulation
CLS code for hybrid
manufacturing
Unified
5 axis
Deformable
Geometrical
Model
5 axis machining generation
5 axis machining simulation

5 Axis Cladding 五轴熔覆
Nozzle Perpendicular to Deposition喷
嘴五轴垂直于淀积

Deposition Track Road Shape
沉积的轨迹道路形状
Melting Pot Simulation 熔炉模拟

Start 5 Axis Machining
启动五轴加工

5 Axis Flank Milling
五轴侧铣

Clear Surface Details
明确的表面细节

Multiple Material Deposition
五轴多材料沉积
46

Test Case Vase 工艺瓶案例

5 Axis Remanufacturing
五轴再制造受损叶片叶尖
Import a scanned blade model in STL format
导入STL格式叶片扫描模型
Automatic generate 3 axis milling, 3-5 axis cladding
and 5 axis machining toolpath
自动生成3-5轴覆层和加工刀路
Simulate 3 axis milling to remove the tip模拟铣削
Simulate 3-5 axis cladding to build the tip模拟熔覆
Simulate 5 axis machining to clean the remaining
stock 模拟5轴加工清理余量

Cut off Damaged Blade Tip
切掉受损叶片叶尖

3 Axis Cladding on Blade Tip
叶片叶尖三轴熔覆

5 Axis Cladding on Blade
叶片五轴熔覆

5 Axis Milling to Clear Remains
五轴铣削来清除容差

5 Axis Milling to Clear Remains
五轴铣削来清除遗迹

Finishing with 5 Axis Milling
用五轴铣削精加工

5 Axis Cladding on Blade Tip
叶片叶尖五轴熔覆

Higher Precision Finishing
高精密加工

Layered Manufacturing Simulation
三维打印分层制造仿真

Adaptive Slicing Algorithm
自适应的切片算法

Support Structures 支撑结构

Tree Supports 树枝形支架
73

Surface Texture Predication
表面形貌的预测

Industry Strength Application
工业应用

Summary
Unified hybrid manufacturing model 统一的混合制造
模型
Multiple materials and processes simulation多种材料
和多种工艺模拟
Cladding track road shape熔覆轨迹形状
Ten times faster than CAM simulation速度高十倍
 Voxel model based simulation基于体素模型仿真
 Swept volume speeding algorithm扫掠体超速算法
 Toolpath modeling and simulation刀路建模与仿真
Automatic generation of 5 axis toolpath生成5轴刀路

Special Thanks: Zhang Xiao Tian
Senior Application Engineer
Engineering Solutions
Hitachi Sunway Information Systems (Singapore) Pte Ltd
140 Paya Lebar Road
#06-01/02 AZ@Paya Lebar
Singapore 409015
Main: +65 6718 2300 Fax: +65 6718 2301
DID: +65 6718 2314
Mobile: +65 9127 2151
zhangxt@hitachi-sunway-is.com
http://www.hitachi-sunway-is.com

Special Thanks: Silas Daiber
Head of Additive Manufacturing Center
Research & Development
DMG MORI Singapore PTE. LTD.
3 Tuas Link 1, SG-638584 Singapore
Tel.: +65 6660 6669 Fax: +65 6660 6699
Mobile: +65 9272 8584
silas.daiber@dmgmori.com
www.dmgmori.com

5 axis 3 d hybrid manufacturing automation 五轴三维增减材复合制造自动化

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