High-end R&D and advanced manufacturing solutions based on forward design and additive manufacturing

Additive manufacturing refers to the digital manufacturing technology based on the discrete-stacking principle of similar mathematical calculus, which is realized by the three-dimensional data driving of parts and computer automatic control to realize precise and controllable, layer-by-layer increase of materials to directly manufacture parts. Compared with the reduction of materials and other materials, the additive manufacturing is mold-free and tool-free, but it is not just a new manufacturing process, but a new round of technological revolution and industrial revolution will change the way human production is produced. And an important engine of life and a disruptive technology system. This subversiveness is reflected in, in addition to the advantages brought by this new manufacturing process, and more importantly, it realizes the integration of structural design, high-performance material preparation, complex component manufacturing, and macroscopic structure. Design and microscopic material preparation bring revolutionary changes.

The additive thinking behind additive manufacturing technology is a revolution in design. It completely opens up the design shackles, DFM (manufacturing), DFA (assembly) and other traditional design methods based on reduced material manufacturing, and the designers can really Returning to user needs, performing functional-oriented design (DFF) or additive-oriented design (DFAM), in terms of value, function, and energy, makes design and process, design, and manufacturing no longer a causal and sequential relationship. It is a mutually energetic living system that realizes low-cost innovative design and rapid manufacturing of large/ultra-large components or structural systems, complex/ultra-complex components or structural systems, multi-variety and small-volume individualized products in a natural way. Extraordinary structures enable extraordinary functions.

After many years of practical application experience based on system engineering, product forward design and simulation analysis, combined with the profound application of the additive industry, Anshi Asia Pacific has developed an innovative business model based on the overall optimization of resources, and proposed a forward design and The high-end R&D and advanced manufacturing solutions for the manufacturing of materials provide solutions that can be implemented in the design and manufacturing integration of “Made in China 2025”.

First, the technical architecture

The technical framework for high-end R&D and advanced manufacturing solutions based on forward design and additive manufacturing is based on the general framework of the modern science discipline system, including the foundation of the “three-level bridge” proposed by Qian Xuesen under the guidance of the system perspective in the early 1980s. Discipline level - systems engineering, mathematics, physics, materials science, etc., information enabling environment - data collaboration for digital main lines and digital hygiene, cloud manufacturing based on big data and Internet of Things, technical discipline layer - TRIZ and Technological innovation and management, topology optimization, engineering simulation, knowledge engineering, engineering technology layer - forward design consulting system based on system engineering, product material process integration design methodology and process system combination configuration Advanced manufacturing process integration preferred consulting system, advanced material preparation research and development service system, engineering practice layer - industrial product-oriented solution system (such as aircraft, aircraft engine, automobile, mold, etc.), industrial chain-oriented solution system ( Public institutions such as entrepreneurs, consumers, higher education and vocational training

Second, the process system

The overall flow of the design for additive manufacturing is shown in Figure 2. This process covers the requirements analysis, architecture design, detailed design and other processes of the product. In practical applications, this guiding process needs to be combined with the system engineering process framework of the dual V model. Figure 3 shows the design flow for additive manufacturing based on the systematic design of the German standard mechanical product VDI2221. It can be considered that this is the actualization of the VDI2221 in the development stage.

Supporting the above-mentioned top-level processes for additive manufacturing design are several specialized sub-processes, such as MBSE-based system modeling, topology optimization and simulation and creation design integration process (Figure 4), and the creation design process for additive manufacturing. (Figure 5) and so on.

The design process of additive manufacturing based on VDI2221 is shown in Figure 3 below:

The combination of forward design and additive manufacturing is applied to different types of data integration, analysis, mining and display scenarios such as engineering massive data, industrial big data, and Internet big data. It is applied to product model data management, integration and collaboration. It is applied to knowledge management, knowledge engineering, various professional database/knowledge base construction, and even applied to business intelligence and strategic decision-making of group companies.

Third, the success story

1, the robot arm additive material forward design case

Figure 5 is a robot arm topology optimization - process and evolution:

The effect of the additive design and the test by actual additive printing is shown in Figure 6:

2, the shunt cover and the positive design case

The shunt cover has corresponding design inputs and requirements:

Load: 1.5g acceleration, ultimate load 1kg

Goal: Precision high stiffness placement, reduced quality

Purpose: Optimize stiffness

The effect of the additive design and the test by actual additive printing is shown in Figure 8:

Fourth, the conclusion

The relationship between additive manufacturing and traditional manufacturing can be analogized to the relationship between classical physics and atomic physics. The future development of additive manufacturing must also have broad and far-reaching prospects like atomic physics and quantum physics. The advanced manufacturing technology system based on additive thinking is the “second chance window” for the transformation and upgrading of China's manufacturing industry, which makes it possible for us to change lanes. Additive thinking is a revolution that returns to the essence of design, breaks the mindset, releases design freedom, and stimulates creativity. This revolution is not only a revolution of manufacturing, but also a revolution of design, not only for product R&D designers. It is the entire population. The lean R&D advocated by Anshi Asia Pacific and the high-end R&D and advanced manufacturing solutions based on forward design and additive manufacturing are bound to undergo the baptism of practical application in this revolution, and then continue to improve and mature, based on positive design and additive The manufacturing of high-end R&D and advanced manufacturing solutions is the latest interpretation of Anshi Asia Pacific's initial and vision of “Promoting Lean Spirit and Creating Smart Industry”.