Hybrid additive and subtractive manufacturing
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design and manufacture of physical structures using hybrid additive and subtractive manufacturing include, in one aspect, a method including: obtaining data for 3D geometry of a part; simulating at least a portion of a manufacturing process that includes adding first material in a first stage and removing second material in a second, subsequent stage, where the second material includes a portion of the first material, removing the second material includes blending between the material added in the first and second stages, and thermal effects of adding and removing the material in the first and second stages is simulated; and adjusting an amount of the portion based on results of the simulating to prevent deviation of the part from the three dimensional geometry that results in not enough material being available for the blending.
1 . A computer-implemented method comprising:
obtaining data for three dimensional geometry of a part to be manufactured from a material by a hybrid additive and subtractive manufacturing system comprising an additive manufacturing tool and a subtractive manufacturing tool using a manufacturing process comprising a series of two or more stages, each of the two or more stages comprising adding the material with the additive manufacturing tool and removing some of the material with the subtractive manufacturing tool;
simulating, in accordance with the data and a physical property of the material, at least a portion of the manufacturing process that includes adding first material using the additive manufacturing tool in a first stage of the two or more stages and removing second material using the subtractive manufacturing tool in a second stage of the two or more stages, wherein the first stage precedes the second stage, wherein the second material includes a portion of the first material, wherein removing the second material comprises blending between the material added in the first and second stages, and wherein the simulating comprises simulating thermal effects of adding and removing the material in the first and second stages;
adjusting an amount of the portion of the first material included in the second material based on results of the simulating, in accordance with the physical property of the material, to prevent deviation of the part from the three dimensional geometry, during the portion of the manufacturing process, that results in not enough material being available for the blending; and
manufacturing the part by the hybrid additive and subtractive manufacturing system using the adjusted amount of the portion of the first material included in the second material for blending between material added in the first and second stages.
2 . The computer-implemented method of claim 1 , wherein the portion of the manufacturing process comprises adding third material using the additive manufacturing tool in the second stage of the two or more stages and removing fourth material using the subtractive manufacturing tool in the first stage of the two or more stages, the first material includes the fourth material, the second material includes a portion of the third material, the simulating comprises simulating vibration experienced during at least the removing of the second material, and the method comprises:
modifying two or more tiers of the part to be manufactured and thus the two or more stages responsive to the vibration being excessive.
3 . The computer-implemented method of claim 2 , wherein simulating vibration comprises simulating instability during cutting based on predicted cutting forces and dynamic response.
4 . The computer-implemented method of claim 1 , wherein adjusting the amount of the portion of the first material included in the second material comprises increasing an overbuild amount of the first material, in relation to the three dimensional geometry of the part, to be added using the additive manufacturing tool in the first stage of the two or more stages.
5 . The computer-implemented method of claim 1 , wherein the portion of the manufacturing process comprises adding third material using the additive manufacturing tool in the second stage of the two or more stages and removing fourth material using the subtractive manufacturing tool in the first stage of the two or more stages, the first material includes the fourth material, the second material includes a portion of the third material, and adjusting the amount of the portion of the first material included in the second material comprises decreasing an amount of the fourth material and increasing the portion of the first material included in the second material.
6 . The computer-implemented method of claim 1 , wherein the part is a turbine rotor comprising a hub and blades designed to operate in a high temperature environment, and the simulating comprises simulating machining of the blades built with the additive manufacturing tool, in the two or more stages, on top of blade roots included as integral portions of the hub.
7 . The computer-implemented method of claim 1 , wherein the hybrid additive and subtractive manufacturing system comprises one or more computer processing apparatus including at least one non-transitory computer-readable medium encoding a computer aided design program operable to perform the obtaining, the simulating, the adjusting, and the manufacturing.