5 axis hybrid manufacturing model and simulation

Unified Model and Simulation of Hybrid Manufacturing Processes

Mr. Liu Peiling Principal Research Engineer

Singapore Institute of Manufacturing Technology

71 Nanyang Drive, Singapore 638075

Tel: 65-67938356 Mobile: 65-90123598 Fax: 65-67916377

[email protected] http://simtech.a-star.edu.sg

Confidential © 2015 All rights reserved

Singapore Institute of Manufacturing Technology Slide 2

Hybrid Manufacturing

The Hybrid Manufacturing is the blend of subtractive and additive manufacturing processes.

Additive manufacturing processes have seen nowadays as an upward trend in complex and structurally sound industrial applications.

At the same time, there is still an open ground in modelling and simulation techniques when applied to these processes.



Commercial Solutions A quick reuse of conventional material removal model

without an realistic additive features

Simplified deposition track road shape

Mike Nicholson, Sales & Marketing Director of MachineWorks says, "We have always been able to deliver material addition as well as material removal but recently we have seen the demand for additive simulation rocketing".

http://www.google.com.sg/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwigxK3b76_JAhVFto4KHV-VCs8QjRwIBw&url=http://www.polygonica.com/polygonica-blog/preparing-for-the-next-manufacturing-revolution/&psig=AFQjCNFLPRQaUrsSA0maSvhpDkF7Ol6KTg&ust=1448688572992941



Our solutions:

A unified hybrid manufacturing model

Multiple materials and surface textures

Composite, surface painting, marking, ……

Multiple processes

3-5 axis machining

2.5 axis 3D printing, such as SLA, SLS, LOM,……

3-5 axis cladding, welding……



5 Axis Cladding Nozzle Perpendicular to Deposition



Deposition Track Road Shape Melting Pot Simulation



Start 5 Axis Machining



5 Axis Flank Milling



Clear Surface Details



Multiple Material Deposition

10



Test Case Vase



5 Axis Cladding on Blade Tip

Import a scanned blade model in STL format

Automatic generate 3 axis milling, 3-5 axis cladding and 5 axis machining toolpath

Simulate 3 axis milling to remove the tip

Simulate 3-5 axis cladding to build the tip

Simulate 5 axis machining to clean the remaining stock



Cut off Damaged Blade Tip



5 Axis Cladding on Blade



5 Axis Milling to Clear Remains



Finishing with 5 Axis Milling



Higher Precision Finishing



5 Axis Machining Simulation



Start to Cut



Roughing within 3 Minutes



Toolpath and in Process Model



Finishing with Multiple Operations



Zoom In Details



See from Another Angle



Industry Strength Application



Summary

Unified hybrid manufacturing model

Multiple materials and processes simulation

Cladding track road shape

Ten times faster than NX 3D simulation

Voxel model based simulation

Swept volume speeding algorithm

Toolpath modeling and simulation

Automatic generation of 5 axis toolpath

5 axis hybrid manufacturing model and simulation

Engineering