Project Details
Projekt
Simulation-based process design for machining additively manufactured components
Applicant
Professorin Dr.-Ing. Petra Wiederkehr
Subject Area
Metal-Cutting and Abrasive Manufacturing Engineering
Term
since 2025
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 512940050
Laser deposition welding with wire-shaped material enables the production of complex components by using an industrial robot, for example, by depositing in different spatial positions. Even if near-net-shape production is achieved, post-processing is often necessary in order to ensure the required tolerances and surface qualities, especially for functional and contact surfaces. For this purpose, milling is used as for post-processing in this research unit (RU). To ensure that the component can be additively manufactured and post-machined in a single clamping setup, robot-assisted milling is to be qualified for this application as part of the RU. This robot-assisted machining in particular poses special challenges, e.g., due to comparatively low rigidity. For this reason, methods for a simulation-based process design will be investigated. On the one hand, the aim is to evaluate and identify advantageous process scenarios that can be taken into account as boundary conditions when optimizing or adapting the NC paths. On the other hand, by characterizing the requirements of the machining process, boundary conditions will be determined, which should already be taken into account in the design of the additive components. Relevant process characteristics of the additive process used, such as the resulting shape deviations that occur, must be taken into account during machining post-processing. Modeling such effects in a machining simulation requires, e.g., the conduction of basic experimental studies on the machining behavior of additively manufactured components. In particular, the development of a new workpiece model to represent process-related shape deviations and the necessary research into an approach for multiscale component digitization represent major challenges for the further development of the milling simulation. For the digitization, a separate component measurement outside the production cell has to be avoided since this can lead to increased process times and, as a result of the clamping and unclamping of the workpieces, to considerable inaccuracies during post-processing. On this basis, methods for the simulation-based process design will be investigated, with which, for example, dimensionally accurate machining can be carried out.
DFG Programme
Research Units
