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In this paper, a new CAM planning strategy for removal of support structures is presented. Since such a task is usual in post-processing of parts fabricated with additive manufacturing, the developed approach is about a toolpath planning algorithm suitable for generic robotic cells that can be equipped with a chiseling holder. The 6-axis toolpath generation was used to define spatial paths of the tool tip and proper orientation of the chisel tool. The chisel can be orientated with a certain angle to the machined surface ensuring a gouge-free and collision-free positioning. Removability of different support structures was experimentally validated. [ABSTRACT FROM AUTHOR]

Achieving a sustainable value creation with innovative technological means based on principles of living nature is the goal of Biological Transformation (BT). The three essential principles of BT: Bio-Inspiration, Bio-Integration and Bio-Interaction, enable the implementation of biologically transformed materials, structures and processes. BT is an emerging concept in the field of Industrie 4.0, taking a particular emphasis on product creation, but its specific influence and the potential for process planning in manufacturing are still underrepresented in research. Regarding the BT of the manufacturing industry, the goal in process planning is to support the user towards the most sustainable processes. Due to the current lack of profound systematical approaches process planning strongly depends on the user's level of knowledge of conventional manufacturing processes, which can be inefficient in terms of environmental sustainability. Therefore, this paper methodically investigates the potential for process planning using a taxonomy of principles for the BT of the manufacturing industry. These categorized modes of action for a BT are linked to key performance indicators within the economic and environmental sphere. As a result, expedient approaches for a biologically transformed process planning are uncovered, which address the principles of adaptation, self-adaption and bio-intelligent process engineering to affect the energy consumption, machining time and process stability. Furthermore, first concept ideas for an integrated solution are presented and a basic validation is provided. [ABSTRACT FROM AUTHOR]

The concept of digital twins promises high potentials for product design, manufacturing, user experience and recycling. Thus, digital twins have received increasing interest in academia and industry. However, the actual benefits of digital twins remain in many cases unclear. This article aims to summarize selected recent developments in this field and demonstrate use cases from different phases of the product lifecycle. For that purpose, examples from the design, manufacturing, use and recycling phase are presented. In a subsequent discussion, ideas for new value stream patterns using digital twins are envisioned and research questions are derived. [ABSTRACT FROM AUTHOR]

In this paper, the presented approach resolves important aspects that appear in the process planning for multi-axis Direct Laser Additive Manufacturing: smoothing of the nozzle orientation along the toolpath to reduce deviation of the laser spot's surface speed, redistribution of the toolpath points on the surface to ensure robust processing of the points by the machine tool, collision avoidance between the nozzle and the workpiece by adjustment of the nozzle orientation. Collision avoidance penalizes the lateral tilting to minimize the change of the laser spot size due to tilting and, therefore, it has reduced its impact on the process. [ABSTRACT FROM AUTHOR]

Abstract In contrast to standard layer based additive manufacturing methodologies, multi-axis material deposition can print structures without the need for support material. However, this method is jeopardized by potential collisions between a depositing unit (nozzle, wire, power and powder sources, etc.) and the already deposited material. The goal of this research is to initiate development of a methodology to check manufacturing feasibility of geometries and generate subsequent process planning strategies. The paper describes a geometry-based concept to decompose the product geometry into discrete volumes by using space partitioning with infinite planes and considering advantages and constraints of multi-axis additive manufacturing. The discrete volumes are used to generate process planning variants and to compute and generate boundary conditions for such process planning strategies. The algorithm generates multi-axis slices that require no support structures because of relative nozzle/workpiece orientation. In addition, the planning tackles more complex scenarios, in which overhangs, nozzle orientation, and gravity can be considered. [ABSTRACT FROM AUTHOR]

5-axis machining operations bring new challenges for predicting cutting forces. Complex tool workpiece engagements and tool orientations make it difficult to adapt 3-axis process models for 5-axis operations. A new model is developed to predict cutting forces with arbitrary tool/workpiece engagement and tool feed direction. A discretization approach is used, in which the tool is composed of multiple cutting elements. Each element is processed to determine its effect on cutting forces, and global forces are determined by combining the elemental effects. Cutting tests are conducted to verify force predictions, where the tool/workpiece engagement is provided through a geometric software application. [ABSTRACT FROM AUTHOR]

Abstract: This paper describes the development of a five-axis tool path generation algorithm for the machining of complex shaped parts using flat-end tools. In order to reduce the machining time and to ensure optimal quality, the step-over is optimized in each tool contact point. This step-over calculation is obtained through the integration of a newly developed algorithm for material removal simulation. The latter is performed by calculating swept volumes which represent tool motions interpolated according to the machine kinematics. The developed algorithm has been implemented for contour like (spiral) strategies and validated through the machining of an industrial example. [Copyright &y& Elsevier]