Geometrical Locating Scheme for Complex Hybrid Manufacturing: Multiple Additive Manufacturing and Machining

Abstract

The technology of additive manufacturing is rapidly developing as one of the most sustainable alternatives for the traditional manufacturing processes. Additive manufacturing technologies offer numerous advantages such as weight reduction, design freedom, reducing material waste and so on. But to manufacture complex components, the traditional manufacturing processes are still needed to obtain the final desired geometry. DiSAM is one such project that is happening in Sweden, aiming to improve the technology readiness of additive manufacturing processes. A complex aircraft component is being manufactured in this project using both additive manufacturing and traditional manufacturing processes. In this process of complex manufacturing where, multiple additive manufacturing processes and machining processes are involved, the effect of the locating scheme in each step of manufacturing process plays a vital role in providing the desired geometrical accuracy. This thesis work was carried out to develop a locating scheme that was most suitable to follow in this complex manufacturing process chain. The component from the engine exit structure of a gas turbine engine which is termed as "H-Sector" was the product in focus. Information was collected through interviews with the stakeholders of the DiSAM project. The manufacturing process flow was studied to finalize on the parameters that affects the geometrical accuracy at different manufacturing steps. The critical areas of the components were identified which needs to be focused in developing locating scheme at each manufacturing step. The software RD&T was used in evaluating the locating schemes. Different locating scheme strategies were developed. Sensitivity analysis was carried out to compare between the strategies and finalizing on the final locating scheme. This thesis outcome will help in making decisions regarding the locating scheme for the DiSAM project. The same method can be followed in developing different locating scheme for different geometry in the future.