Topic 2: Manufacturing and Measurement Process Control

(Team led by S. Lavernhe)

Keywords: laser powder bed fusion (LPBF), concentrated energy deposition (WAAM, WLAM), 5-axis machining, CAD/CAM, in-situ / in-process instrumentation, real-time control, digital twin

Actors : Olivier Bruneau, Kevin Godineau, Sylvain Lavernhe, Nicolas Muller, Yann Quinsat, Christophe Tournier

Multi-scale control and management of geometry, material, and energy (model and data approaches)

➢ Manufacturing strategies
(optimal trajectories, process integration through control, measurement, and simulation, model reduction)

➢ Entity-based approaches
(knowledge models, implicit representations, learning: unsupervised, multimodal, transfer, real/right-time product integration)

➢ Single/multi-process manufacturing sequences
(multi-criteria optimization based on technical, economic, and environmental factors, manufacturing specifications, key characteristics)

Real-time control in PBF-LB

➢ Open numerical control
(reverse engineering, data reading/writing, integration and parameterization of predefined trajectories)

➢ Interpolation strategies
(Mastering CAM <-> CNC interaction) <-> Real-world trajectories, trajectory optimization under process and machine constraints)

➢ PBF-LB Digital Twin
(Architecture, Synchronization, Lifecycle)

Qualification of measurement systems (In-Situ / Ex-Situ)

➢ Complex Surfaces
('Information-rich' metrology, surface, entity, and part software standards, 'robust' surface finish parameters for AM)

➢ Metrology 5.0
('Smart' metrology for optical and tomographic measurement, trusted AI, the role of humans: cobots and Augmented Reality)

➢ 'Metrological' Digital Twins
(measurand, measurement process, measurement system, embedded CNC/Robot measurement)
Envoyer des commentaires

Highlights:

Additive manufacturing

The laboratory's activities in additive manufacturing focus on high-energy processes such as laser powder bed fusion and concentrated energy material deposition. They concern in particular the calculation of 8-axis material deposition trajectories as well as the optimisation of process parameters (laser power, geometric uncertainties and scanning speed, etc.), trajectories and their execution in order to control material health and microstructure and to produce near net shape geometries.

This work is mainly based on the experimental platforms of the laboratory and its partners, i.e. the laser powder bed fusion additive manufacturing machine (FormUp350) and its instrumented control bench, the hybrid additive (wire laser) and subtractive (milling) robotic cell, the WAAM cell of the Additive Factory Hub industrial platform and the Paris-Saclay additive manufacturing initiative partner laboratories resources

Multi-axis machining

In high-speed multi-axis machining, the work focuses on the optimisation of the steps in the manufacturing process and in particular the machining paths and the control. It is based on the modelling of the process and the articulated mechanical structure from a geometric, kinematic and dynamic point of view. The experimental campaigns are based on the Mikron UCP710 and DMG HSC75 high-speed machining centres as well as on the open numerical control developed in the laboratory.

Simulation models and methods, software prototypes

The laboratory develops models, simulation methods and software prototypes, based on experimental manipulations. The optimisation of the control of manufacturing resources is supported by the exploitation of multi-physical models on the one hand and the integration and development of multi-sensor/multi-scale in-situ measurement techniques to implement data-driven approaches on the other. All of these models and data enable us to develop the building blocks of digital twins for parts, production systems and processes. This work takes the form of national and international academic and industrial partnerships (AddUp, Missler Software, Safran, IRT SystemX, Dassault Systèmes, etc.).