A decomposition method for efficient manufacturing of complex parts

ABSTRACT

This paper presents a method to decompose three dimensional complex parts into readily available stock material to take advantage of advanced joining to build up a rigid assembly. The method generates many alternative assemblies by decomposing the solid geometry iteratively with cutting planes. Each assembly is then evaluated based on cost. The process continues until the developed search algorithm converges on a near optimal solution. Application of this method will reduce material waste, thus reducing per part processing time, energy consumption, and associated production costs. Example parts for a variety of metals show how the computational tool finds near optimal solutions for complex three dimensional solids.

GRAPHICAL ABSTRACT

KEYWORDS:

• Decomposition
• assembly optimization
• design automation
• friction welding
• advanced joining

Acknowledgements

The research work presented in this paper was supported by the Boeing Company and the Oregon Metal Initiative (OMI). Views expressed in this paper are those of the authors and do not necessarily reflect the opinions of these supporters. The authors would like to acknowledge the larger project team, consisting of Prof. Karl Haapala, Prof. David Kim, Steven Lindberg, and Harsha Malshe, who were invaluable in the development of this concept and its implementation. In addition, the authors would like to thank Matt Carter, Stefanie Meier, Kevin Slattery, Eric Eide, Ryan Hanks, and Chris Carpenter for their guidance.

ORCID

Brandon R. Massoni http://orcid.org/0000-0002-0946-5205

Matthew I. Campbell http://orcid.org/0000-0003-1296-6542