Patent Application
20160325380
The present invention relates to an improved method of manufacturing large three dimensional components. More particularly, the present invention relates generally toward a method of manufacturing combining direct material deposition with metal forming to provide more efficient manufacturing processes.
Manufacturing large mechanical components has always proven difficult, particularly when various three dimensional elements are required of a particular component. Previously, only casting could provide three dimensional elements of a large component. Casting complex three dimensional elements is slow and cost prohibitive often requiring complex dies known to be expensive. It would be preferable to stamp, roll form or extrude a large three dimensional component to achieve mass reduction and efficiency savings. However, it has not been feasible to form three dimensional elements upon a component formed from sheet metal without performing complex welding to attach these elements to a component. Even exceedingly expensive progressive dies have limitations preventing their use in many applications
One method of forming a complex three dimensional component with the use of direct material deposition or 3D printing techniques. However, 3D printing large components, based on volume of printing required has also proven inefficient and cost prohibitive limiting broader acceptance as a viable manufacturing alternative for large and complex objects.
Therefore, it would be desirable to develop a method of forming a three dimensional component, including the three dimensional elements required of that component in a rapid, cost efficient manner.
A method of forming a three dimensional component includes first predetermining a geometric configuration of the component. A first portion of the component is preformed and includes a first material. The first portion is preformed by one of casting, forging, stamping, roll forming, extruding, or molding. A second portion of the component includes a second material that is deposited upon the first portion of the component using direct material deposition process. In this manner, the first portion is reconfigured to the predetermined geometric configuration of the component. The physical characteristics of the component are enhanced by the second portion providing a geometric configuration to the component not possible of preforming the first portion using conventional forming techniques.
A novel approach for manufacturing a three dimensional component of the present application combines the best features of conventional metal forming with the advanced techniques of direct material deposition. The difficulties associated with attempting to cast or form three dimensional elements of a three dimensional component are overcome by first preforming a portion of the component and second performing direct material deposition to achieve advanced three dimensional shape of the component. As such, complex, large three dimensional components can now be manufactured in an efficient, cost effective manner.
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
The invention of the present application provides a method for improved manufacturing of large three dimensional components by combining with the advances associated with 3D printing and additive manufacturing with conventional metal forming processes. As such, metal forming processes included, but not limited to, casting, forging, rolling, roll forming, stamping, hot forming, are all included within the scope of this application.
The combination of conventional manufacturing processes with direct material deposition provides the ability to advance quality of the ensuing products. Direct material deposition processes disclosed in U.S. Pat. No. 6,925,346 which discloses closed-loop, rapid manufacturing of three-dimensional components using direct metal deposition, and U.S. Pat. No. 8,878,094 covering part-geometry independent real time closed loop weld pool temperature control system for multi-layer DMD process are contemplated for use in the method of the present application, and the contents of these patents are incorporated herein by reference.
The first embodiment of the present invention is shown in
Referring now to
In this embodiment, the sheet metal blank defines a first portion 26 of the desired component 10 including a first material and the direct metal deposition provides a second portion of the desired component 10 from a second material. The second material, in one embodiment, is substantially the same as or identical to the first material. Alternatively, the second material is different than the first material to provide further enhancements to the physical characteristics and material properties of the component 10 when the predetermined geometric configuration is developed by the direct material deposition of the second material.
For example, the first material is selected from a light weight or low cost alloy to achieve either mass or cost objectives. The second material is selected to provide different material characteristics from an alloy that would be cost prohibitive to form the entire component from. Thus, the method of the present invention provides the ability to optimize both performance and cost of a component. Further, the second material can be selected from an alloy or an alloy enhanced with ceramics or other materials to further improve the physical characteristics and material properties of the component by way of direct material deposition.
A method of forming the component 24 of the further embodiment is generally shown at 36 of
Alternatively, the nozzle 14 deposits the first layer of material 40 upon the first side 42 of the first portion 26 and the fixture 38 rotates the first portion 26 so that the nozzle 14 deposits a first layer of material upon the second side 44 of the first portion 26. In this manner, the first layer 40 deposited upon the first side 42 of the first portion 26 cools prior to receiving a second layer of the second material. As represented in
In a similar manner as set forth above, a second portion 54 is deposited by the nozzle 14. The nozzle 14 moves along the additional first portion 47 providing material deposition of the second material over the first material defining the additional first portion 47. One or more nozzles 14 may be used to deposit the material defining the second portion 54 upon the additional first portion 47. Furthermore, simultaneous use of two nozzles 14 further increases the efficiency when forming the component 46 of the additional embodiment. Still further, the second portion 54 may also be deposited upon an inner surface 56 of the first portion 47 if affixed to an articulating arm (not shown). In this manner, complex geometric configurations of the second portion 54 can be formed upon a roll formed or extruded first portion 47 that were not previously achievable. In addition, deposition of a third material is also within the scope of this invention to provide still further benefits to the component 46.
The invention has been described in an illustrative manner, and is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. It is now apparent to those skilled in the art that many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that the invention may be practiced otherwise and is specifically described, and still be within the scope of the present application.
The present application claims priority to U.S. patent application Ser. No. 62/158,762 filed May 8, 2015, the contents of which are included herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62158762 | May 2015 | US |
