Executive summary
I. Introduction
2. Overview of Ideal Material Parts (IFMC)
Third, homogenization theory and mesostructure design
Fourth, the digital manufacturing under the philosophies
V. IFMC digital design and manufacturing research content
6. Application of IFMC digital design and manufacturing technology
VII. Brief introduction of relevant research work of this research group
I. Introduction
1.1 Manufacturing science is moving towards full digitalization
Modern CAD technology has enabled the Boeing B-777 aircraft to be designed and manufactured without using a single drawing. All design, pre-assembly, and simulation tests are performed on a computer.
To date, CAD design systems have only been able to digitally describe the surface information of parts, and it is difficult to describe the material information inside the parts (such as non-homogeneous functionally graded materials).
The tiering of RPM is also limited to homogeneity, lacking performance and organizational information.
1.2 The era requires the integration of materials and parts, integrated design and manufacturing technology
Usually the product consists of one or more parts, and the quality of the parts and manufacturing directly affects the performance and quality of the product.
Until now, almost all parts have been composed of single or homogeneous materials;
Advances in science and technology require higher comprehensive mechanical properties of product parts.
General elemental materials - it is difficult to meet the requirements of high single index and good comprehensive performance (such as the brittleness of ceramics, the low modulus of organic materials, the low specific strength of metal materials, etc.).
Functional composite materials—exploring the design and manufacturing methods of ideal functional material parts that can be used to complement each other and have designability, has become one of the research topics.
2. Overview of Ideal Material Parts (IFMC)
2.1 Basic meaning
IFMC - Ideal Functional Material Components
According to the best use functional requirements of the parts, a new type of material parts, ideal (functional) material parts, are designed and manufactured, with gradient-changing tissue components and a regular distribution of fine structures.
2.2 Ideal material parts illustration
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2.3 New challenges to design and manufacturing theory and technology
The traditional manufacturing technology is mainly characterized by the separation of materials and parts manufacturing. Generally, different types of raw materials are manufactured first, and then selected according to the performance requirements of the parts, and then the required parts are obtained by the manufacturing method. Only applicable to the manufacture of homogeneous material parts.
The external shape information, internal material organization information, manufacturing information and function information of the parts are integrated to carry out a complete digital representation, and the parallel design and manufacture of parts and materials are realized, forming a new digital design and manufacturing technology system.
2.4 Digital design and manufacture of ideal materials
The ideal material digital design and manufacturing refers to unifying the material properties of the parts and the functions of the parts, and fully digitizing them; in the design process, the parallel design of the material structure, function and geometry of the parts; in the manufacturing process According to the digital design information, the parallel construction of the internal material structure and the three-dimensional assembly of the part is completed.
Third, homogenization theory and mesostructure design
The properties of a material generally depend on the form of the fine structure on its small size, including the volume ratio of the component material phase, the density distribution law, the mesostructure feature or the junction type.
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Fourth, the digital manufacturing under the philosophies
Rapid Prototyping Technology (RP&M), a typical digital manufacturing technology under the philanthropy of additive manufacturing, is considered a major breakthrough in the field of manufacturing technology for nearly two decades.
The more mature RP&M molding technologies include: stereo light modeling SL, selective laser sintering SLS, layered solid manufacturing LOM, fused deposition manufacturing FDM, and 3D printing 3D-P.
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Combining RP&M's philosophy with technology and traditional material removal techniques and cladding techniques, using composite molding methods and digital forming techniques for multi-component components, the ideal material, optimum performance and ideal geometric accuracy of the part Three-dimensional rapid prototyping and moldless manufacturing are possible.
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V. IFMC digital design and manufacturing research content
Unify the structural, material, manufacturing, and functional features of the part for digital representation;
In the design process, the integrated (fusion) design of the external geometric topological shape of the part and the fine structure of the internal material structure according to the functional requirements;
In the manufacturing process, according to the digital design information, the internal structure of the part and the uniform manufacturing of the three-dimensional shape are completed at one time.
5.1 Theories and methods of digital design and manufacturing integration
Establish a mathematical model of the relationship between the fine structure of the material and the macroscopic properties of the part;
CAD model representation theory and method for heterogeneous (functional gradient) and anisotropic material parts;
According to the mechanical, thermal, electromagnetic and other functional requirements of the part, the external geometric topological shape of the part and the internal material organization and fine structure integration (fusion) design technology are carried out.
5.2 Basic research on integration and integration of digital design and manufacturing of materials and parts
Digital trajectory planning for direct forming of ideal material parts and pre-processing method of CAD data;
Modeling and performance simulation of interface behavior and material fusion stacking process during direct forming of composite material parts;
Theory, method and technology for digital stacking forming of ideal materials (non-homogeneous, multi-layer complex and functionally graded materials) parts;
Post-processing technology of parts, etc.
Sixth, IFMC digital design and manufacturing technology application
6.1 Laser Rapid Prototyping Technology for High Performance Metal Parts
Using the basic principle of RPM, through the laser melting-rapid solidification layer-by-layer deposition of metal materials, the rapid solidification and high-performance near-net-formed parts with complete compactness, fine structure, uniform composition and excellent performance can be directly formed. "High-performance material preparation and rapid prototyping of complex parts" is a combination of "modelless", "non-contact" and "no pollution" IFMC digital design and manufacturing technology.
1995-1998: Under the auspices of the US Naval Research Office (ONR) and the Defense Advanced Research Projects Agency (DARPA) Mantech, Dual Use Science and Technology, the research on laser rapid prototyping technology for aviation titanium alloy structural parts was carried out.
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6.2 Laser Rapid Prototyping TiAl/Ti Gradient Blade Parts
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6.3 Precision Spray Forming Technology
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Based on bionic manufacturing technology, by self-organizing mechanisms and modes that mimic the growth and development of living organisms, the self-growth of parts under the control of the intrinsic information model can be realized, and parts with arbitrarily complex or biological characteristics can be manufactured. The ideal goal of pursuing.
7. Related research work of this research group
Since 1997, the research and innovation team led by Guo Dongming of Dalian University of Technology has supported many major natural science fund projects, face projects (59775065, 59351510, 59975015, 50275018) and the Doctoral Program Fund of the Ministry of Education (1999014102). In the following, a number of basic theoretical studies have been carried out on the digital design and manufacture of ideal material parts and related topology optimization and rapid prototyping.
7.1 Research on topology optimization of micro and fine structures
Small and micro flexible machines are constructed based on theoretical methods such as perturbation theory, structural topology optimization homogenization method, generalized optimization technique, operator semigroup theory and orthogonal wavelet and semi-orthogonal spline wavelet. Mathematical models and calculation methods for structural optimization design;
Solved the problems of "checkerboard format" and "sensitivity of computing grid" which are common in topology optimization results. The micro-clamp nuclear micro-motion workbench was developed, and the theory and technology of parallel design and manufacture of structure and material integration were developed. .
The project was funded by the National Science Foundation in 1997, project number 59975065.
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7.2 Research on digitization and processing of ideal material parts
An ideal material part design framework consisting of two parts: performance design and material design is proposed.
Based on the simple division of the geometric bottom space, the ideal material part information digitization scheme for uniformly expressing homogeneous materials, composite materials, functionally graded materials and functional fine structures using periodic functional fine structures;
Developed CAD data exchange format and adaptive slicing algorithm for ideal material parts in digital design and manufacturing.
The project was funded by the National Natural Science Foundation of China (59975015 and 50275018) and the Doctoral Fund of the Ministry of Education (1999014102).
7.3 Research on CAD Model of Ideal Material Parts
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7.4 Numbers of geometric information for ideal material parts
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7.5 Digitization of material information for ideal material parts
Periodic functional meso-structure (PMS) material representation scheme model.
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7.6 Special Processing Research for Rapid Manufacturing
For practical applications, some research work has been carried out in the exploration of high-efficiency, high-precision composite and combined processing technology to form a special processing technology system for rapid manufacturing.
This project is a key project funded by the National Natural Science Foundation of China in 1999, 59,351,010.
7.7 Performance-oriented digital manufacturing of complex curved parts
National 973 Program: “Digital Manufacturing Basic Research†– New Principles and New Methods for Digital Precision Machining of High Performance Complex Surfaces.
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Future prospects
Looking into the 21st century, as long as people combine advanced manufacturing technology, material science methods, computational mechanics, and physics theory, and integrate difficult theory with modern manufacturing technology, we will be able to develop this ideal material part scientifically. The design and manufacturing technology has made people's long-term vision of efficiently designing and manufacturing new material parts based on mechanics and electromagnetic properties. In the near future, it is possible to manufacture new material parts according to the required functions, just like designing and building houses in the near future. .
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