Interrupted hybrid manufacture (IHYM)

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.