Graduate Thesis Or Dissertation


Automated Rapid Manufacturing Feedback for Design Considering Advanced Joining Processes Public Deposited

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  • As manufacturing advancements continue to develop, designers must be able to consider these technologies during the design process. Unfortunately, many of these new technologies, such as additive and advanced joining, have many nuances that require expert knowledge to effectively apply. Additionally, new design techniques, such as topology optimization, allow users to create geometries that are traditionally not manufacturable. The approach presented in this thesis bridges the gap of expert knowledge between component design and a new advanced manufacturing technique, specifically linear friction welding to form monolithic components from multiple individual raw material blanks. The first step of the approach analyzes a part geometry to determine the unmachinable regions. This is done by converting an input tessellated shape into a voxelized solid and analyzing different axial cutting tool approach directions that could occur during a milling operation. Areas that the tool cannot access remain, which indicate regions of unmachinable solids. These solids are then used to determine areas where pre-joining machining could occur, taking advantage of the capabilities of linear friction welding. This is done using an existing part decomposition method while using a two-objective search optimizing total cost of manufacturing and total unmachinable volume. Decomposition configurations yield new set-ups of individual sub-volumes to determine unmachinable volume remaining and manufacturing plans are created by rebuilding the configurations to determine total cost of manufacturing. Results of the work demonstrate the ability to determine manufacturing plans and the potential tradeoffs of complex geometries, processing, and costs.
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  • Ongoing Research
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  • 2018-08-22 to 2019-09-23



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