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

[email protected] http://simtech.a-star.edu.sg

mailto:[email protected]



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

http://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 ISO ISO APT/CL 3D

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


Singapore Institute of Manufacturing Technology Slide 13 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".

http://www.google.com.sg/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwigxK3b76_JAhVFto4KHV-VCs8QjRwIBw&url=http://www.polygonica.com/polygonica-blog/preparing-for-the-next-manufacturing-revolution/&psig=AFQjCNFLPRQaUrsSA0maSvhpDkF7Ol6KTg&ust=1448688572992941



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

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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

[email protected]

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

[email protected]

www.dmgmori.com

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

Engineering

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