Synergy in Additive Manufacturing and Machining of Complex Design Topologies
Loading...
Date
2019-06-25
Authors
Zhu, Yanli
Journal Title
Journal ISSN
Volume Title
Publisher
University of Waterloo
Abstract
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.
Description
Keywords
additive manufacturing, machining, design rules, synergy process workflow, laser powder bed fusion