Convergent Manufacturing: A Future of Additive, Subtractive, and Transformative Manufacturing Proceedings of a Workshop (2022) / Chapter Skim
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3 Process Hybridization in One Platform
3 Process Hybridization in One Platform
Pages 26-47
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From page 26... ...
Introducing the theme of the keynote presentation, he noted that democratization of innovation aims to move innovation from the smallest enterprise to production and operations, and ultimately to the population. DEMOCRATIZATION OF INNOVATION Tracy Frost, Director, Office of the Secretary of Defense Manufacturing Technology Keynote speaker Frost explained that merging different materials, processes, and systems requires collaboration among several communities, many of which are accustomed to working in siloes.
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From page 27... ...
She outlined the objective of the MII program to create enduring resources for these advanced manufacturing stakeholders across the nation. Frost remarked that the MII model is intended to bridge the "valley of death," where technology cannot be scaled up or adopted in the United States, or where funding ceases and technology stalls.
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From page 28... ...
She presented several examples of MII efforts in education and workforce development. First, Advanced Functional Fabrics of America embedded research fellows at defense facilities, providing cross-training opportunities.
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From page 29... ...
PANEL 3: HYBRID MANUFACTURING PROCESSES Michael Sealy, Associate Professor of Mechanical Engineering, Purdue University Sealy noted his interest in hybridization as a means to solve problems related to degradable implants, as well as those related to the food chain, supply chain, wear able structures, and lightweight structures. For example, when it costs $9,000/kg to launch something into space but only $5/kg for an airplane to fly from one city to another, the urgent need for lightweight structures as well as remote manu facturing (i.e., the ability to produce anything anywhere, whether in space or in a deployment zone)
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From page 30... ...
With hybrid additive manufacturing, however, it is possible to combine manufacturing processes (e.g., deep rolling, milling, peening) to make changes layer by layer and to print the desired mechanical properties.
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From page 31... ...
The Colorado School of Mines is now working with Georgia Tech to add interferometry -- enabling surface roughness measurement of the additive plus machine surfaces. Stebner said that near-term goals for hybrid manufacturing include moving beyond the paradigm of two tools/processes and one material.
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From page 32... ...
He stressed that all of these innovations require the ability to tailor existing alloys or grade between multiple materials within a single build. Paul showed that his research on polymetal additive manufacturing demon strates that it is possible to build high-quality metal matrix composites such as oxide dispersion–strengthened stainless steel.
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Mary Clare McCorry, Director of Technology and Process Development, Advanced Regenerative Manufacturing Institute (ARMI) , BioFabUSA McCorry outlined the biological considerations for hybrid manufacturing, emphasizing that biology makes a system more complicated, with concern for
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From page 34... ...
In the case of personalized medicine, she continued, materials have to be tracked throughout the manufacturing process to ensure that the right product is delivered to the right patient. McCorry's moonshot is to simplify the process so that it is more accessible, to be able to deploy in remote environments, to develop consistent and quality products, to create autonomous and closed processes, to enable predictive under standing, to engage in informed decision making, and to create flexible processes and personalized medicine.
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From page 35... ...
Paul remarked that the design of hybrid manufacturing machine tools extends from an understanding of the physics that must be governed in the context of a manufacturing process. Thus, he suggested that "manufacturing process design" precede machine tool design and become part of a common engineering lexicon as a means for achiev ing manufacturing innovation.
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From page 36... ...
Sealy explained that although most universities have secured a metal additive manufacturing system over the past 5 years, it is too complex and unsafe for many at the bachelor's level to use, which raises questions about how students will be trained to do metal additive manufacturing. To expand convergent manufacturing, he continued, more accessible and lower cost systems would lead to increased educational opportunities at the undergraduate level and make it less difficult to hire people with metal additive manufacturing skillsets.
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From page 37... ...
PANEL 4: DESIGN AND MODELING OF HYBRID MANUFACTURING PROCESSES Julie Chen, Vice Chancellor for Research and Innovation, University of Massachusetts Lowell Chen emphasized that funding for fundamental research and development has encouraged the creation and evolution of models amidst the modification of materials and the emergence of more complex structures. As these models continue to evolve, AI and machine learning play an important role; for example, additive manufacturing processes and materials combinations are becoming so complex that machine learning coupled with physics-based models offers a means to optimize and move beyond the make-and-break process and product development stage.
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From page 38... ...
Benedict explained that most manufacturing for the Air Force has to be quali fied for air worthiness, which is a rigorous process related to stability, producibil ity, characterization, predictability, and maintainability. Modeling and advanced design have the potential to accelerate the acceptance of advanced manufacturing concepts, he continued, particularly in convergent manufacturing.
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Paul Witherell, Mechanical Engineer, Measurement Science for Additive Manufacturing Program, Systems Integration Division, Engineering Laboratory, National Institute of Standards and Technology Witherell offered a systems perspective of design and modeling for hybrid manufacturing processes. He explained that systems integration activities have long benefitted from and contributed to maturing design, modeling, and simula tion capabilities (e.g., virtual to virtual and virtual to physical)
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From page 40... ...
Witherell emphasized that advanced hybrid manufacturing systems extend beyond the additive and subtractive. Advanced hybrid manufacturing systems cre ate unique systems challenges, which can be overcome by solving evolving systems problems: these problems become increasingly complicated as the components of the system continue to increase in size, complexity, and scope while increased demands are placed on control.
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From page 41... ...
. He suggested continuous and repeated movement through the following cycle to optimize parameters toward certification: a model or a digital twin, process parameters that interface with the physical process to drive the system, in-process monitoring, big data, machine learning and AI, simulation OPTIMIZATION MODELS / DIGITAL TWINS SIMULATION & ANALYSIS PROCESS PARAMETERS PEOPLE EDUCATION / WORKFORCE DEVELOPMENT MACHINE LEARNING / AI PHYSICAL PROCESS BIG DATA PROCESS MONITORING FIGURE 3.1 Execution of hybrid manufacturing.
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From page 42... ...
Keogh described a current LIFT hybrid manufacturing cell with an additive/ subtractive approach that is working toward monitoring thermal and melt pool data, torch parameters, and machining chatter, and feeding those data back through a centralized data hub that is interrogated with machine learning algorithms to improve function. Moonshot projects include any synthesis of additive, subtractive, or metamorphic capabilities to control the thermal history and microstructure of components, which could provide information on the properties that could be yielded and subsequent performance.
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Kelly invited the panelists to share their key takeaways from the session. Chen asserted that workforce development is a top priority.
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From page 44... ...
He also supported more multidisciplinary education to better understand hybrid systems and the future of advanced manufacturing. Benedict explained that design fulfills a requirement, and modeling informs the risk of achieving that requirement; risk acceptance is key to moving faster.
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From page 45... ...
McCorry noted that three-dimensional printing and additive manufacturing are being used to create personal therapeutics that are being filed as one-offs for particular patients, even though the same manufacturing approach is used every time. At some point, she continued, the therapeutic should not be con sidered a one-off, and the material should be qualified to accelerate approvals and avoid the need to run a full clinical study for each use of the material.
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From page 46... ...
Sealy added that the earliest patents for hybrid additive manufacturing processes emerged from China and the United Kingdom, many of which were driven by aerospace applications. He mentioned that some of the old est work was published internationally and funded by the military overseas -- the United States is lagging.
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From page 47... ...
2019. Modeling thermal and mechanical cancellation of residual stress from hybrid additive manufacturing by laser peening.
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