Interrupted hybrid manufacture (IHYM)
Lead Participant:
DMG MORI UK LIMITED
Abstract
The vision is to develop single platform machine for Interrupted HYbrid additive / subtractive Manufacture with integrated inspection technologies -- for the purposes of this bid, defined as IHYM. This will be based on blown powder additive and 5-axis mill-turn machining. We will develop process capability in four application areas where we have identified a business need:
§ Interrupted processing: the creation of complex internal geometries which can only be achieved through IHYM.
§ 'Lumps and bumps': Working with slimline forgings or castings and adding external features such as bosses, elbows or ribs to improve material yield and enable rapid customisation of products.
§ Graded Functionality: control localised material properties through control of lay conditions in conjunction with bulk material - single or multi material.
§ Titanium: process redesign to enable IHYM with Titanium
To deliver these additive capabilities, real-time process information must be obtained and mined for insights. Process monitoring will be linked to real-time or event-based control of the platform through a novel rule-based system which will provide both user feedback and increased machine autonomy. A completely new field is the development of combined process models which will provide insights into the effect of IHYM on part metallurgy. A novel feature-based cost modelling system will also be developed.
The project starts at a manufacturing readiness level (MRL) 4 and using the market-leading hybrid platform from DMG Mori, and will deliver hybrid machining techniques to MRL6 for four additive capabilities. Key objectives and innovative developments are:
§ Novel through-process models and decision systems
§ Through-process monitoring and control, fed by insights from models
§ Connected system to fuse knowledge and rules with data analytics
§ Completely new IHYM ability for Titanium
§ Manufacturing strategy for intermittent deposition / machining due to heating and cooling effects
§ Manufacturing capability for graded materials
§ Development of adjacent processes (powder characterisation and recommendations for standards, novel heat treatments)
§ Design rules for IHYM
Project impacts include:
§ Acceleration of IHYM uptake because of the automated decision tool and cost model
§ Reduced material consumption in aerospace and oil and gas components by 60%, linked to the near-net additive manufacture of raw components, thereby replacing or simplifying castings and forgings.
§ Reduced tooling and associated costs.
§ 30% reduction in production costs due to the introduction of IHYM technologies, linked to optimised manufacturing conditions and tool path optimisation.
§ Interrupted processing: the creation of complex internal geometries which can only be achieved through IHYM.
§ 'Lumps and bumps': Working with slimline forgings or castings and adding external features such as bosses, elbows or ribs to improve material yield and enable rapid customisation of products.
§ Graded Functionality: control localised material properties through control of lay conditions in conjunction with bulk material - single or multi material.
§ Titanium: process redesign to enable IHYM with Titanium
To deliver these additive capabilities, real-time process information must be obtained and mined for insights. Process monitoring will be linked to real-time or event-based control of the platform through a novel rule-based system which will provide both user feedback and increased machine autonomy. A completely new field is the development of combined process models which will provide insights into the effect of IHYM on part metallurgy. A novel feature-based cost modelling system will also be developed.
The project starts at a manufacturing readiness level (MRL) 4 and using the market-leading hybrid platform from DMG Mori, and will deliver hybrid machining techniques to MRL6 for four additive capabilities. Key objectives and innovative developments are:
§ Novel through-process models and decision systems
§ Through-process monitoring and control, fed by insights from models
§ Connected system to fuse knowledge and rules with data analytics
§ Completely new IHYM ability for Titanium
§ Manufacturing strategy for intermittent deposition / machining due to heating and cooling effects
§ Manufacturing capability for graded materials
§ Development of adjacent processes (powder characterisation and recommendations for standards, novel heat treatments)
§ Design rules for IHYM
Project impacts include:
§ Acceleration of IHYM uptake because of the automated decision tool and cost model
§ Reduced material consumption in aerospace and oil and gas components by 60%, linked to the near-net additive manufacture of raw components, thereby replacing or simplifying castings and forgings.
§ Reduced tooling and associated costs.
§ 30% reduction in production costs due to the introduction of IHYM technologies, linked to optimised manufacturing conditions and tool path optimisation.
Lead Participant | Project Cost | Grant Offer |
---|---|---|
DMG MORI UK LIMITED | £293,528 | £ 146,764 |
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Participant |
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GOODRICH ACTUATION SYSTEMS LIMITED | £188,761 | £ 94,381 |
ADVANCED MANUFACTURING (SHEFFIELD) LIMITED | £402,744 | £ 281,921 |
XPERTRULE SOFTWARE LIMITED | £241,942 | £ 169,359 |
JEMTECH (UK) LIMITED | £35,012 | £ 24,508 |
SECO TOOLS (U.K.) LIMITED | £252,338 | £ 126,169 |
CRAFTSMAN TOOLS LIMITED | £245,514 | £ 147,308 |
UNIVERSITY OF SHEFFIELD | £496,028 | £ 496,028 |
INNOVATE UK | ||
DOUG MARRIOTT ASSOCIATES LTD |
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