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The production of large components currently requires cost-intensive special machine tools with large workspaces. The corresponding process chains are usually sequential and hard to scale. Furthermore, large components are usually manufactured in small batches; consequently, the planning effort has a significant share in the manufacturing costs. This paper presents a novel approach for manufacturing large components by industrial robots and machine tools through segmented manufacturing. This leads to a decoupling of component size and necessary workspace and enables a new type of flexible and scalable manufacturing system. The presented solution is based on the automatic segmentation of the CAD model of the component into segments, which are provided with predefined connection elements. The proposed segmentation strategy divides the part into segments whose structural design is adapted to the capabilities (workspace, axis configuration, etc.) of the field components available on the shopfloor. The capabilities are provided by specific information models containing a self-description. The process planning step of each segment is automated by utilizing the similarity of the segments and the self-description of the corresponding field component. The result is a transformation of a batch size one production into an automated quasi-serial production of the segments. To generate the final component geometry, the individual segments are mounted and joined by robot-guided Direct Energy Deposition. The final surface finish is achieved by post-processing using a mobile machine tool coupled to the component. The entire approach is demonstrated along the process chain for manufacturing a forming tool.

Micro-EDM is widely used in micro-hole and 3D micro-structures. However, the application of Micro-EDM is limited due to the scarcity of micro-electrodes. Therefore, the preparation of micro-electrodes has been one of the difficult and hot issues in the field of EDM. In this study, EDM is used to make micro-electrodes. In order to ensure the high dimensional accuracy of the micro-electrode, a parametric study is conducted by replicating a copper electrode with a diameter of 1mm to a steel block by the method of segmented manufacturing. The relationships between the drilled cavities on the block and the features on the micro-electrode are established. The effects of machining parameters (current, pulse width and pulse interval) on the response variables (electrode bottom side length, electrode length, material removal rate, surface roughness and side length deviation rate) are investigated. Current and pulse width are found more dominant as compared to other selected process parameters. Using optimized parameters from the parametric study, a copper micro-electrode of 46µm bottom side length and 1773µm length is fabricated. A micro-channel with a length of 1200µm, a width of 85µm and a depth of 35µm was processed on the copper sheet. [ABSTRACT FROM AUTHOR]