The aim of this work is to determine how to combine a subtractive process (HSM) and an additive process (SLS) to realize tools (dies or molds). In fact, the design and manufacturing of tools may be optimized with hybrid and modular points of view. Tools are not seen as single pieces but as 3-D puzzles with modules; each module is manufactured by the best process. So a new methodology is proposed: the most complex-to-manufacture areas of a tool are determined (based on a manufacturability analysis from tool CAD model) and a hybrid modular tool CAD model with a reduced manufacturing complexity is proposed. In this paper, a manufacturing complexity evaluation methodology is exposed. Manufacturability indexes have been developed, and an interface is created to calculate them directly from a tool CAD model. This new approach provides an accurate view of which parts of the tool have to be improved in order to reduce manufacturing difficulties. Then modular and hybrid points of view allow designing a hybrid modular tool which will be less difficult-to-machine than the first single-piece tool, and consequently be manufactured at lower cost, in the shortest lead-time and with high degrees of flexibility and quality. Two simple examples have been treated to illustrate the possibilities of this new methodology. To have a more detailed view of manufacturing complexity, more accurate manufacturability indexes may be calculated, with other parameters involved and organized with fuzzy logic, so further researches will be conducted to develop new manufacturability indexes (based on material information and specifications). A study has to be done in order to be able to compare different indexes between themselves. Assembly constraints generated by a hybrid modular design have also to be taken account, and the methodology will be applied an industrial die from automotive industry.


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    Title :

    Manufacturing complexity evaluation for additive and subtractive processes: application to hybrid modular tooling


    Additional title:

    Bewertung der Fertigungskomplexität für additive und subtraktive Prozesse: Anwendung auf eine hybride, modulare Werkzeugausrüstung


    Contributors:
    Kerbrat, O. (author) / Mognol, P. (author) / Hascoet, J.Y. (author)


    Publication date :

    2008


    Size :

    12 Seiten, 8 Bilder, 5 Tabellen, 17 Quellen


    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English




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