Synergy in Additive Manufacturing and Machining of Complex Design Topologies
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Additive manufacturing (AM) enables freedom of design, part complexity and customization with minimal added cost, light weighting, design for function, and part consolidation. It is gaining increasing interests in the fields of biomedical, aerospace, automotive, tooling, and heat exchange systems where small batch productions of customized parts with high value are usually in demand. AM, in general, is considered to have great potential in complementing conventional manufacturing methods. Functional parts with high strength to weight ratio generated using structural topology optimization can be eventually realized by AM. Limitations of AM parts related to surface finish and dimensional accuracy are likely to be overcome by post-machining of critical features and surfaces in order to achieve specific tolerance and surface quality. To minimize trial and error efforts, AM and post-machining simulations are essential for effective planning of the synergized processes. The goal of this study is to propose a process workflow which can be used as a guideline for successful production of complex parts manufactured via AM, particularly laser powder bed fusion (LPBF), and post-processed via CNC (computer numerical control) machining. The workflow is deployed and iterated through a case study of manufacturing a surgical navigation tracker, where the holistic manufacturing process involves digital design utilizing structural topology optimization, AM simulation, machining planning, fabrication, and validation.
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Yanli Zhu (2019). Synergy in Additive Manufacturing and Machining of Complex Design Topologies. UWSpace. http://hdl.handle.net/10012/14777