Design for Wire + Arc Additive Manufacture: design rules and build orientation selection

Wire + Arc Additive Manufacture (WAAM) is an additive manufacturing technology that can produce near net-shape parts layer by layer in an automated manner using welding technology controlled by a robot or CNC machine. WAAM has been shown to produce parts with good structural integrity in a range of materials including titanium, steel and aluminium and has the potential to produce high value structural parts at lower cost with much less waste material and shorter lead times that conventional manufacturing processes. This paper provides an initial set of design rules for WAAM and presents a methodology for build orientation selection for WAAM parts. The paper begins with a comparison between the design requirements and capabilities of WAAM and other additive manufacturing technologies, design guidelines for WAAM are then presented based on experimental work. A methodology to select the most appropriate build orientation for WAAM parts is then presented using a multi attribute decision matrix approach to compare different design alternatives. Two aerospace case study parts are provided to illustrate the methodology

Implementation of hierarchical design for manufacture rules in manufacturing processes

In order to shorten the product development cycle time, minimise overall cost and smooth transition into production, early consideration of manufacturing processes is important. Design for Manufacture (DFM) is the practice of designing products with manufacturing issues using an intelligent system, which translates 3D solid models into manufacturable features. Many existing and potential applications, particularly in the field of manufacturing, require various aspects of features technology. In all engineering fields geometric modelling wluch accurately represents the shape of a whole engineering component has become accepted for a wide range of applications. To apply DFM rules or guidelines in manufacturing processes, they have to be systematised and organised into a hierarchical rule system. Rules at the higher level of the hierarchical system are applied to more generic manufacturing features, and specific rules are applied to more detailed features. This enables the number of rules and amount of repetition to be minimsed. Violation of the design for manufacture rules in the features, their characteristics and manufacturing capabilities are further examined in this hierarchical system. Manufacturabillty analysis, such as production type, materials, tolerances, surface finish, feature characteristics and accessibility, are also taken into consideration. Consideration of process capabilities and limitations during the design process is necessary in order to minimise production time and as a result, rnanufactunng cost. The correct selection of manufacturing processes is also important as it is related to the overal cost. As a result of this research, a hierarchical design for manufacture rule system is proposed which would aid designers in avoiding designs that would lead to costly manufacturing processes

Similarity measures for mid-surface quality evaluation

Mid-surface models are widely used in engineering analysis to simplify the analysis of thin-walled parts, but it can be difficult to ensure that the mid-surface model is representative of the solid part from which it was generated. This paper proposes two similarity measures that can be used to evaluate the quality of a mid-surface model by comparing it to a solid model of the same part. Two similarity measures are proposed; firstly a geometric similarity evaluation technique based on the Hausdorff distance and secondly a topological similarity evaluation method which uses geometry graph attributes as the basis for comparison. Both measures are able to provide local and global similarity evaluation for the models. The proposed methods have been implemented in a software demonstrator and tested on a selection of representative models. They have been found to be effective for identifying geometric and topological errors in mid-surface models and are applicable to a wide range of practical thin-walled designs

Development of Innovative Heat Sinks for Power Electronics Cooling within the More Electrical Aircraft

Peer ReviewedPostprint (published version

A novel design process of low cost 3D printed ambidextrous finger designed for an ambidextrous robotic hand

This paper presents the novel mechanical design of an ambidextrous finger specifically designed for an ambidextrous anthropomorphic robotic hand actuated by pneumatic artificial muscles. The ambidextrous nature of design allows fingers to perform both left and right hand movements. The aim of our design is to reduce the number of actuators, increase the range of movements with best possible range ideally greater than a common human finger. Four prototypes are discussed in this paper; first prototype is focused on the choice of material and to consider the possible ways to reduce friction. Second prototype is designed to investigate the tendons routing configurations. Aim of third and fourth prototype is to improve the overall performance and to maximize the grasping force. Finally, a unified design (Final design) is presented in great detail. Comparison of all prototypes is done from different angles to evaluate the best design. The kinematic features of intermediate mode have been analysed to optimize both the flexibility and the robustness of the system, as well as to minimize the number of pneumatic muscles. The final design of an ambidextrous finger has developed, tested and 3D printed

E -commerce for the metal removal industry

The popularity of outsourcing fabrication introduces a problem, namely an inevitable loss of data as information is translated from design to fabrication or from one system to another. Unsatisfactory information, delivered to the outsourcing facility, and inefficient communications between design and fabrication certainly cause enormous economic losses from late product delivery or bad product quality. To overcome these data transferring problems and to improve communications between the design and fabrication sides, a design and manufacturing methodology for custom machined parts in E-Commerce is suggested and implemented in this dissertation. This methodology is based on the idea of a Clean Interface like the Mead-Conway approach for VLSI chip fabrication [MEAD81]. Essential design information for fabricating parts properly with NC (Numerical Controlled) milling machines is expressed in machining/manufacturing features, fabrication friendly terminologies, and is represented by a new language called NCML (Numerical Control Markup Language). NCML is based on XML (Extensible Markup Language)---the document-processing standard proposed by the World Wide Web Consortium (W3C). NCML is designed to include the minimum requisite information necessary for the manufacturer to produce the product. The designer defines NCML, which overcomes geographical separation between design and manufacturing, and minimizes unnecessary interactions caused from lack of information. To prove the possibility of custom machine part fabrication and E-Commerce with NCML, three software systems are implemented. These three systems are FACILE/Design, FACILE/Fabricate, and E-Mill. FACILE is a prototype CAD/CAM system developed to verify NCML feasibility as an Electronic Data Interchange (EDI) format. FACILE/Design is a system based on manufacturing features like holes, contours, and pockets. It can be used to create geometric models, verify the design, and create NCML files. The NCML file is imported by FACILE/Fabricate and turned into G-codes by applying appropriate cutting conditions. Simplified machining simulation and cost estimation tools using NCML inputs are also developed to show some examples of NCML applications that can help design and manufacturing activities. To demonstrate how NCML could be used in a web-based application, an E-Business model called E-Mill has been implemented. E-Mill is a market place for machined parts whose data is encoded in NCML. To make E-Mill a feasible E-Commerce model, two-way communication based on NCML data and the visualization of 3D geometric models in the Virtual Reality Modeling Language (VRML) are equipped with a competitive matchmaking mechanism. In this dissertation, a whole system based on NCML bridges the gap between design and manufacturing. As a part of the NCML validation process for the new system, the pros and cons of NCML design features are discussed. A system for cost estimation is calibrated and compared to real cutting results for the purpose of validation

A concurrent approach to automated manufacturing process planning

textWith the increasing demand of fast-paced and hybrid manufacturing processes in modern industry, it is desirable to expedite the iterations between design and manufacturing through intelligent computational techniques. In this research, we propose a concurrent approach of this kind to streamline the design and manufacturing processes. With this approach, a CAD design is automatically analyzed in terms of its manufacturability in the early design stage. If the part is manufacturable, a set of process plans optimized in time, cost, fixture quality and tolerance satisfaction are reported in real time. If the part is not manufacturable, the potential design changes are provided for better manufacturing. In the approach, the geometric information of 3D models and the empirical knowledge in manufacturing processes, fixtures, and tolerances are combined and encapsulated into a graph-grammar based reasoning. The reasoning systematically extracts meaningful manufacturing details that later constitute complete process plans for any given solid model. The plans are then evaluated and optimized using a specially designed multi-objective best first search technique. The complete approach enables a concurrent and efficient manufacturability analysis tool that closely resembles real manufacturing planning practice. Numerous case studies with real engineering parts are presented to characterize the novelty and contributions of this approach. The optimality of the suggested plans is verified through computational comparisons, and the practicality of the plans is validated with hands-on implementations on the shop floor.Mechanical Engineerin

Decision support system for form verification of manufactured parts.

The form verification of manufactured parts is a process composed of a set of operations that are expensive and yet add no value to the product. Yet, the resources used to inspect the parts add a small but significant amount of noise that can affect the outcome of the process. For this reason, this research provides guidelines to effectively perform the inspection process by suggesting new mathematical models and approaches that can be used for the creation of a decision support system that can assist in the verification of the accuracy of machined parts.This research proposes two approaches to improve the robustness of the mathematical models from the noise induced by the inspection process. The Dynamic Angle Approach (DAA) and the Free Form Orientation approach (FFO) presented here focus on finding the parameters of the axes and origin of the form that counteract the inaccuracies of the inspection equipment.In summary, this research suggests formalized methods for feature extraction, sampling, path planning, and form fitting, although the last mentioned received the most attention. It is believed that this comprehensive, integrated analysis will lead to the development of a decision support system.The proposed approaches and mathematical models were verified using measurements from features that were perfectly aligned with the coordinate system of the inspection equipment and from features that were intentionally misaligned. The results showed that the models were accurate and robust enough to estimate the parameters and zone of error of the form features and they performed better than existing models.The main goal of this research is to develop procedures that are simple to implement but at the same time are robust enough to provide reliable information that help the metrologist to make accurate decisions about the inspected parts. Form features such as spheres, cylinders, cones, frustums, and torus forms are commonly used to design complex parts. However, the procedures to verify most of these form features have not been developed yet by the national standards. Therefore, this research proposes new mathematical models that combine the concepts of analytic geometry and optimization to provide optimal solutions