WO2025166141A1 - Systems for metamorphic manufacturing - Google Patents

Abstract

In some aspects, the techniques described herein relate to a system for metamorphic manufacturing (100) including: an enclosure; a plurality of sensors (101) for monitoring a workpiece; a plurality of actuators (103)for deforming the workpiece; a thermal component (102) for heating the workpiece; a positioning component (104) for positioning the workpiece; a compliance mechanism for protection the positioning systems (703); and one or more computing devices (105) for receiving data from the plurality of sensors and for controlling the plurality of sensors, the plurality of actuators, the thermal component, and the positioning component. Algorithms that control the deformation and material structure development are an integral component of the system and may function either from an initial program, or may use sensing data from the system to make real-time decisions.

Description

SYSTEMS FOR METAMORPHIC MANUFACTURING

GOVERNMENT SUPPORT CLAUSE

[0001] This invention was made with government support under grant number 128744 awarded by the National Science Foundation. This invention was made with government support under grant/contract number 2133630 awarded by the National Science Foundation and grant/contract number SP4701-22-D-0120 awarded by the Department of Defense. The government has certain rights in the invention.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent No. 63/627,268, filed on January 31, 2024, entitled "BLACKSMITHING ADD ON KIT FOR CNC MILLING MACHINE." This application further claims priority to U.S. Provisional Patent No. 63/571,784, filed on March 29, 2024, entitled "EFFICIENT SYSTEMS FOR METAMORPHIC MANUFACTURING." This application further claims priority to U.S. Provisional Patent No. 63/691,393, filed on September 6, 2024, entitled "A PLATFORM FOR METAMORPHIC MANUFACTURING." The contents of all are hereby incorporated by reference.

BACKGROUND

[0003] Metamorphic Manufacturing or Robotic Blacksmithing generally uses automated systems to carry out manufacturing operations like blacksmithing, which can at once provide shape and refine material. Through digital control, key operations, sequences, and quality control, operations are transferred to the software, allowing relatively unskilled operators to efficiently manufacture high-quality parts even in high-mix environments. [0004] What is desired is an equipment suite that is easily reproducible and scalable, leveraging lightly modified common, Commercial-Off-The Shelf (COTS) equipment to efficiently produce a range of components at high efficiency and modest training requirements for operators.

SUMMARY

[0005] Described and disclosed herein are systems and methods of metamorphic manufacturing for hot metal shaping (forging, bending, piercing) in an appropriate transportable shop to produce components near point of need. This has many advantages, including but not limited to: (1) transfers forging skills to the system, increasing available workforce and their productivity; (2) uses standard engineering materials and heat treatments. This leverages decades of experience in forging and thermomechanical processing; (3) materials agnostic to several classes; (4) Productive. Hundreds of pounds/hours possible with modestly trained operators; (5) Short lead-times: no need for traditional impression dies; (6) Real forging process - superior microstructure and properties; (7) Flexible -wide range of components available from a single numerically controlled system; and (8) Scalable - requires modest changes to existing or COTS equipment.

[0006] In some aspects, the techniques described herein relate to a system for manufacturing including: at least one computing device; and one or more forming actuators mounted on a CNC mill or lathe, wherein the CNC mill or lathe includes: a heater; a tool contact area; a protective compliance mechanism; a machining head; and a plurality of rapidly changeable tools for deforming a workpiece into a desired shape according to a manufacturing process.

[0007] In some aspects, the techniques described herein relate to a system, wherein the heater includes an induction heater and includes multiple coils that can be automatically changed such that only small displacement of the workpiece is required to change from heating to forming.

[0008] In some aspects, the techniques described herein relate to a system, wherein the one or more forming actuators include one or more of a press, a hammer, or a roller.

[0009] In some aspects, the techniques described herein relate to a system, further including a shape determination element for determining a current shape of the workpiece including one or more of a dimensional scanner, a camera, a thermal camera, or a LIDAR or other inspection component.

[0010] In some aspects, the techniques described herein relate to a system, wherein the at least one computing device is adapted to monitor the progress of the workpiece being manufactured by the system according to the manufacturing process and to make one or more adjustments to the manufacturing process based on the monitoring.

[0011] In some aspects, the techniques described herein relate to a system, wherein the system operates in a controlled atmosphere to avoid oxidation.

[0012] In some aspects, the techniques described herein relate to a system, further including an air and/or water spray component that allows for freedom in thermomechanical processing including quenching and tempering.

[0013] In some aspects, the techniques described herein relate to a system, further including a vice, wherein the vice is automated or manual.

[0014] In some aspects, the techniques described herein relate to a system, wherein the system is configured to operate on a workpiece, wherein the workpiece may hang either vertically or horizontally and may be placed on the working surface of a press or an anvil.

[0015] In some aspects, the techniques described herein relate to a system, wherein the one or more forming actuators generate force and displacement signals which are used by the at least one computing device to control the components of the system to deform the workpiece to a desired shape.

[0016] In some aspects, the techniques described herein relate to a system, wherein the system further includes an additive manufacturing component.

[0017] In some aspects, the techniques described herein relate to a system, wherein the additive manufacturing component uses wire-arc.

[0018] In some aspects, the techniques described herein relate to a system for metamorphic manufacturing including: an enclosure; a plurality of sensors for monitoring a workpiece; a plurality of actuators for deforming the workpiece; a thermal component for heating the workpiece; a positioning component for positioning the workpiece; a software component for performing a method of metamorphic manufacturing of the workpiece; and one or more computing devices for receiving data from the plurality of sensors and for controlling the plurality of sensors, the plurality of actuators, the thermal component, and the positioning component to facilitate the method of manufacturing of the workpiece.

[0019] In some aspects, the techniques described herein relate to a system, further including a compliance component, where the compliance component is a Stewart Platform or other multi degree of freedom device.

[0020] In some aspects, the techniques described herein relate to a system, wherein the compliance component includes a helical coil spring-based or pneumatic spring-based compliance device.

[0021] In some aspects, the techniques described herein relate to a system, wherein the positioning component includes a forklift.

[0022] In some aspects, the techniques described herein relate to a system, wherein the plurality of actuators include one or more of a press, a hammer, or a roller. [0023] In some aspects, the techniques described herein relate to a system, wherein the method of metamorphic manufacturing includes transforming a stock workpiece 3D model into a series of intermediate 3D models or waypoints between the stock workpiece 3D model and a given destination 3D model.

[0024] In some aspects, the techniques described herein relate to a system, wherein the method of metamorphic manufacturing further includes finite element or other simulation methods for predicting the outcome of incremental deformations applied to the workpiece, where the outcome includes the 3D shape of the workpiece after deformation as well as the microstructure and mechanical properties after deformation.

[0025] In some aspects, the techniques described herein relate to a system, wherein the method of metamorphic manufacturing further includes generating a series of deformation hit points for the workpiece.

[0026] In some aspects, the techniques described herein relate to a system for manufacturing including: at least one computing device; and one or more presses mounted on a CNC mill, wherein the CNC mill also includes the following attachments: an induction heater (or other heating system including flame, resistance coils, infrared lasers, etc.); a dimensional scanner; a tool contact area; and a machining head.

[0027] In some aspects, the techniques described herein relate to a system, wherein the induction heater includes multiple coils that can be automatically and/or rapidly changed such that only small displacement of the workpiece is required to change from heating to forming.

[0028] In some aspects, the techniques described herein relate to a system, wherein the system operates in a controlled atmosphere to avoid oxidation. [0029] In some aspects, the techniques described herein relate to a system, further including a water spray component that allows for freedom in thermomechanical processing including forming, quenching and tempering.

[0030] In some aspects, the techniques described herein relate to a system, further including a vice, wherein the vice can grip the workpiece for machining, where a stiff fixation of the workpice is requiered, is automated or manual.

[0031] In some aspects, the techniques described herein relate to a system, wherein the press generates force and displacement signals which are used by the at least one computing device to control the components of the system.

[0032] In some aspects, the techniques described herein relate to a system, wherein the system further includes an additive manufacturing component.

[0033] In some aspects, the techniques described herein relate to a system, wherein the additive manufacturing component uses wire-arc.

[0034] In some aspects, the techniques described herein relate to a system, wherein the system further includes a workpiece inspection component.

[0035] In some aspects, the techniques described herein relate to a system, wherein the workpiece inspection component uses one or more of optical inspection means or eddy current inspection means.

[0036] In some aspects, the techniques described herein relate to a system for metamorphic manufacturing including: an enclosure; a plurality of sensors for monitoring a workpiece; a plurality of actuators for deforming the workpiece; a thermal component for heating the workpiece; a positioning component for positioning the workpiece; and one or more computing devices for receiving data from the plurality of sensors and for controlling the plurality of sensors, the plurality of actuators, the thermal component, and the positioning component. [0037] In some aspects, the techniques described herein relate to a system, further including a compliance component.

[0038] In some aspects, the techniques described herein relate to a system, wherein the compliance component includes a Stewart platform-based compliance component.

[0039] In some aspects, the techniques described herein relate to a system, wherein the compliance component includes a helical coil spring-based compliance device.

[0040] In some aspects, the techniques described herein relate to a system, wherein the positioning component includes a forklift or tow-motor with an approprate gripping system affixed.

[0041] In some aspects, the techniques described herein relate to a system, wherein the plurality of actuators include a press, a hammer, or a roller.

[0042] In some aspects, the techniques described herein relate to a system, wherein the thermal component includes a heating coil.

[0043] In some aspects, the techniques described herein relate to a system, wherein the positioning component includes a sliding tool rack that allows for the rapid change between tools.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The components in the drawings are not necessarily to scale relative to each other.

Like reference numerals designate corresponding parts throughout the several views.

[0007] FIG. 1 illustrates elements of an exemplary metamorphic manufacturing system.

[0008] FIG. 2 illustrates an example of implementation of a press and heating coil in a typical lathe configuration suitable for use in the metamorphic manufacturing system. Each may move down the axis and the component has a rotational degree of freedom. To the right is shown a modified lathe attachment with an additional cylinder at 90 degrees to be used for flange formation.

[0009] FIG. 3 illustrates an autonomous forklift concept for metamorphic manufacturing suitable for use in the proposed metamorphic manufacturing system.

[0010] FIG. 4 illustrates an example of a bulkhead suitable for use in the proposed metamorphic manufacturing system. The bulkhead is one of many possible integrally stiffened components and example of how several actuators can be used to provide deformation up the rib. Control of angle and number of actuators is anticipated.

[0011] FIG. 5 illustrates two Stewart platform-based compliance devices suitable for use in the proposed metamorphic manufacturing system. The device 501 on the left uses compressed air springs, while the version 503 on the right uses helical coil springs. Both devices 501 and 503 are capable of providing physical compliance along six degrees of freedom (XYZ displacement, and ABC rotation).

[0012] FIG. 6 illustrates an exemplary single leg from a helical coil spring-based compliance device suitable for use in the proposed metamorphic manufacturing system.

[0013] FIGS. 7, 8, and 9 illustrate renderings of another example metamorphic manufacturing system.

[0014] FIG. 10 is an illustration of a system 100 including an add-on-kit 1003 for blacksmithing.

[0015] FIG. 11 is an illustration of a method 1100 for operating the agility forge.

[0016] FIG. 12 is an illustration of a method 1200 for intermediate model generation.

[0017] FIG. 13 is an illustration of a method 1300 for hit point selection.

[0018] FIG. 14 is an illustration of a method 1400 for tool selection.

[0019] FIG. 15 is an illustration of a method 1500 for hit point culling. [0020] FIG. 16 illustrates an example computing device.

DETAILED DESCRIPTION

[0021] FIG. 1 illustrates an example metamorphic manufacturing system 100, which is also referred to herein as "Agility Forge." The example system 100 includes various components including, but not limited to, sensors 101, thermal control 102, actuators 103 that provide large forces for deformation, robotics 104, and computation 105. The robotics 104 may allow for precise positioning of a workpiece within the actuators 103 and may include computational resources that are central to control and learning (referred to herein as "STARC", short for Sensors, Thermal, Actuators and Control, the typical elements of an agility forge). The robotics 104 and the computing components may be implemented in using one or more computing devices such as the computing system 1100 illustrated with respect to FIG. 11.

[0022] The systems, methods, devices and components of the proposed metamorphic manufacturing system 100 are accomplished in an efficient and high-quality manner comprising productivity maximization, control of shape and microstructure, and new equipment concepts. Each of these elements are discussed further below.

[0023] With respect to productivity maximization, conventionally, there has been little detailed thought into how to design a metamorphic system 100. In all production systems, productivity is a leading success metric and a key element of this is doing the maximum amount of shape change to the material between re-heating events. Systems should be designed for maximum productivity. In traditional forging the leading design metric has been press capacity (tonnage). This largely determined what sizes of components could be produced with a particular forging press. With metamorphic manufacturing deformation is usually incremental, therefore large tonnage is not usually needed, because one can use relatively small tools to sufficiently exceed yield strength. However, because deformation is incremental many discrete forming operations may be required. The total time required to form a part is therefore equal to the time required to initially heat the part and the number of cycles required to form the part. In each cycle there are periods of forming and reheating. This is shown mathematically below:

[0024] Therefore, if the time required for heating is considered to be constant, the variables become the amount of time required forforming and the amount of time required to reposition from one operation to the next. By this analysis the power which is the product of force and displacement-rate is the leading indicator for how quickly plastic deformation can be placed into a part.

[0025] Based on these insights, important elements in designing a productive metamorphic manufacturing system 100 include, but are not limited to:

• Fast, precise motion. Minimize time between heat and deformation and between deformation operations.

• Proximity. Minimize distance and complexity between operations.

• High power and speed. The amount of plastic work that can be done per time is leading process matrix (work/time=power). Note speed and precision as well as actuator power (not tonnage) are the keys to a highly productive system.

• Sufficient press load is required, but power and speed are keys to productivity.

[0026] With respect to control of shape and microstructure: This may be achieved using a well-designed workflow and execution, beginning with consideration of the physical actions needed to give precise shape and the thermomechanical process that gives needed microstructure. Examination of the old school blacksmith artisan and the extensive literature on the thermomechanical processing of metals are great places to start with this problem.

[0027] Basic control of microstructure considers elementary input parameter control, including:

• Appropriate temperature range (inferred by surface temperatures),

• Reaching appropriate levels of effective strain,

• Maintaining mostly compressive deformation.

• Alignment of ei direction (direction of primary, or prinicpal stretching) in production with si (direction of most tensile stress) in service.

[0028] Shape control is accomplished by developing a conceptual path and monitoring and correcting for deviation. In many simple cases monitoring may not be needed and 'open loop' forming instructions may be sufficient, where motions and press displacements are prescribed and simply executed.

[0029] An effective workflow for this design problem is as follows:

• Design stage simulation - simulations in design set nominal process to reach shape and properties. This is typically carried out with non-linear finite element codes such as DEFORM, FORGE or ABAQUS. However, faster approaches leveraging artificial intelligence and reduced order computations are becoming workable.

• In-process-monitoring - monitoring sample shape, temperature, tool loads, time in heating, provide a link to quality control.

• In-process correction - deviation between expected and measured values can cause process modifications to change shape, temperature to meet expected limits. These adjustments are essential control actions in the system.

[0030] With respect to new equipment concepts, equipment configurations need to be consistent with the operations required to make the component. However, it is ideal to make the equipment as simple and compact as possible. One parameter is to have minimal extraneous motion of the part. This permits many possible system designs. The most common theme in these is locating the thermal control, or heating, element very close to the forming element to reduce the amount of time required for transition. For example, new types of equipment that may be added to the system 100 include a lathe, a tow motor, a multi-press, and a compliance device. Other types of equipment may be supported and incorporated into the system 100.

[0031] With respect to lathes, lathe type machine tool configurations may be adapted for numerical forming. The workpiece may be rotated along the primary axis. Existing tooling control and positioning on the normal axis can be used to hold a press and/or induction coil. This provides efficient heating and forming. Furthermore, the observation that most lathes already have an enclosure for coolant and chips provides several other useful possibilities including confining a protective or reducing atmosphere (nitrogen, argon or forming gas) or protecting personnel from potentially dangerous sensing modalities including X-rays used for X-ray diffraction or radiography or other hazardous or noisy processes such as laser shock peening. A purpose-built lathe with included forging capabilities (having one or two compressive press cylinders, possibly with rapidly changing tooling) is a possibility, however, an add on kit for existing CNC lathes is likely possible and may see much more rapid adoption.

[0032] Advantages of adapting commercial lathes includes that they are highly developed, relatively inexpensive, already can control motion along z and precise rotation around the z-axis. Closed-loop control may be needed to correct for unexpected deformation in deformation processing versus the typical subtractive processing.

[0033] In some instances, it may be advantageous to hang the component vertically such that its mass is beneath the point of connection. This can reduce bending moments in part manipulation. While working on the part it may be useful to hang it like a curing a salami sausage rather than trying to support it in a cantilever fashion. This can simplify equipment.

[0034] FIG. 2 illustrates an example of implementation of a press 201 and heating or induction coil 203 in a typical lathe configuration. The press 201 and heating coil 200 may be incorporated into the proposed system 100. Each may move down the axis and may have a rotational degree of freedom. Also shown is a modified lathe attachment 205 (e.g., the flange forming attachment 205) with an additional cylinder at 90 degrees to be used for flange formation, for example.

[0035] With respect to tow motors, forklifts or tow motors are often used with custom gripping tooling to manipulate components in open die forging, particularly when they are very large. Using servo motors, motion capture, lidar, and other 3-dimensional positioning technologies it is possible to use these in an autonomous manner to feed open die forging presses during metamorphic manufacturing by the system 100. FIG. 3 illustrates an example autonomous forklift 300 concept for metamorphic manufacturing in the system 100.

[0036] With respect to multi-presses, in conventional manufacturing systems, some classes of parts such as integrally stiffened panels are difficult to manufacture. Therefore, in some embodiments the system 100 may use multiple actuators 401 to form the ribs on some components. The actuators 401 may be servo electric, servo hydraulic, or kinetic in nature. One, two, three, or even four or more actuators 401 (e.g., the actuators 401A, 401B, 401C, and 401D) may be used and their positions along an axisymmetric support ring 403 may be numerically controlled. This ring 403 should be very stiff and strong. Typical robotic locating operations may be used by the system 100 to move a component being manufactured within the ring 403. A simple configuration of this is shown in FIG. 4, which illustrates an example of a bulkhead 405, one of many possible integrally stiffened components and example of how several actuators 401 can be used to provide deformation up the rib. Control of angle and number of actuators 401 is anticipated. System stiffness and strength could be substituted with inertial control using hammers. This can reduce the size of the equipment needed. With respect to compliance devices, for safety to equipment and personnel, it is often desired to limit the force that a press (for example, often over 10 tons in capacity) may transmit to the positioning robot, or CNC mi ll/lathe, of the system 100. A compliance device should be used between the workpiece and positioning robot in cases where forces cannot be controlled or are unknown. Compliance devices of various kinds are used in robotics. For example, a Stewart Platform can be modified, which provides motion in 6-degrees of freedom to center in a locked position for component location. For examples see FIG. 5. This can have modifiable breakaway loads and torques depending on pneumatic, hydraulic, or spring pressure and varied displacement based on design.

[0037] FIG. 5 illustrates two Stewart platform-based compliance devices. The device 501 on the left uses compressed air springs, while the device 503 on the right uses helical coil springs. Both devices are capable of providing physical compliance along 6 degrees of freedom (XYZ displacement, and ABC rotation).

[0038] The Stewart platform has conventionally been used as an active motion platform for robotic manipulation, finding widespread use in aircraft simulations to provide realistic motion of a simulated cockpit. A Stewart platform generally has six legs attached in a zigzag pattern forming a ring between two plates. The legs are connected to the plates with universal joints/ball and socket joints. Each leg of the Stewart platform can extend or retract, and when all legs are correctly extended or contracted in unison the platform can create motion between the two end plates along six degrees of freedom, XYZ displacement, and ABC rotation.

[0039] The compliance devices shown in FIG. 5 are based on these principals of the Stewart platform, however, the six legs are composed of springlike devices, here referred to as double acting spring mechanisms, which are capable of contraction or extension, but which always return to a fixed length. This action is accomplished by the use of two springs, one always working to extend the leg, and one always working to retract the leg. These springs push against mechanical stops. The user can choose the load with which the springs press against the mechanical stops, referred to as a preset load. When acted upon by an external force these double acting spring mechanisms will remain at a fixed length until the preset load is exceeded, then the leg will contract or extend (depending on the direction of the external force) all the while exerting a restorative force equal to or greater than the preset load. When the external force is removed the double acting spring returns to its original length. When six of these double acting spring mechanism legs are assembled into a Stewart platform, the resulting device will resist external loads until those loads exceed the preset loads of the spring mechanisms, at which point the plates of the platform will move in the direction of the applied load in any of the six degrees of freedom that the load demands, all the while exerting a restorative force. When such an external load is removed, this Stewart platform automatically returns to a fixed neutral position. This Stewart platform with the six double acting spring mechanisms is referred to here as a compliance device.

[0040] A Stewart platform-based compliance device, or other compliance mechanism, is required in a robotic blacksmithing cell to prevent large magnitude and unwanted loading from traveling through the forged workpiece and into the robotic or CNC mill/lathe positioning system. Compliance devices are a protection mechanism for these machines. The return of the compliance device to a fixed neutral position after loading is desired for accurate part positioning and 3D scanning.

[0041] FIG. 6 illustrates a single leg from the helical coil spring-based compliance device. As shown, the device includes a plurality of balls 605, one or more stops 610 (e.g., the stops 601A, 601B, and 601C), and a plurality of springs 603 (e.g., the springs 603A and 603B). The two balls

605 are made of brass or another low friction metal, the ball 605 surfaces are to be placed in sockets on the top and bottom plates of a Stewart platform, where ball and socket joints will be formed. The balls 605 have precision holes bored through them to permit passage of a metal shaft on which the balls 605 may slide with modest friction. The distance between stop 1 and stop 2 determines the set length of the leg. The spring 603A labeled "Spring opposing contraction" is placed between stop 601A and the right ball 605, this spring 603A will always push to keep the right ball 605 against the stop 610B. The right ball 605 may be pushed to the left, reducing the length of the leg, this will be opposed by the spring 603A. The preset load between the right ball and the stop 601B will be determined by the choice of spring between stop 1 and the right ball (spacers may be used to add extra compression to this spring). The distance between the "Extension load setting stop" 601C and left ball 605 will determine the preset load for extension of the leg. Ideally, the preset spring forces will be identical. The left ball 605 may be pushed rightward against the "Spring opposing extension" 603B to extend the leg. The two springs 603 will work together to oppose extension or compression of the two brass balls 605 (which are part of separate ball and socket joints).

[0042] A description of the opposed spring mechanism is provided above. This mechanism may be made using coil springs (as shown in FIG. 6), with pneumatics, or hydraulics, or any other spring-like mechanism. The springs of this mechanism make it passive. Coil springs will increase their restorative force as the legs are extended or compressed, while pneumatic springs may be set up to provide a constant restorative force or an increasing restorative force with increasing extension or compression of the leg. Pneumatics also have the advantage of adjustable preset loads resulting from different input air pressures (from a tank or pressurized line). Both coil spring based, and pneumatic based spring mechanisms would benefit from dampers placed between the balls (or equivalent members) and the stops. Such dampers would prevent hammering against the stops and unwanted oscillations. Additionally, these double acting spring mechanisms may be fitted with switches and/or electrical contacts which open/close when the leg is moved away from its preset length (extension or compression, multiple switches can be used to report the direction). Linear position sensors may also be placed on the legs to determine extension/compression, and with the deformation of all six legs known the position of the Stewart platform-based compliance device can be calculated.

[0043] There are other ways of decoupling, and protecting, the positioning system from possible forces from the main actuator. These include separating the positioning system from the workpiece prior to deformation. Closed loop motion capture or positioning systems may assist in this, and the workpiece can be left in place either by gravity on an anvil-type platen or by using press force to grip the workpiece.

[0044] FIG. 7 is an illustration of another example system 100 for metamorphic manufacturing or agility forge. The system 100 may be adapted to construct a workpiece. The system 100 is relatively agnostic to specific materials being shaped. Steel, aluminum, brass, bronze, nickel-based and other alloy classes may be easily processed by simple selection of the initial workpiece. While varied materials have different strengths, forming temperatures and deformation limits, it is relatively easy to change from one to another.

[0045] The volume of the starting stock material for a workpiece is arguably much more important than the shape of the workpiece. For example, an initial cube of appropriate volume can easily be cogged to a longer shape for subsequent forming.

[0046] The system 100 can easily be adapted to very large component sizes. Commercial induction heating, robotic manipulation and press sizes are routinely scaled to very large sizes and powers. Equipment such as this can be incorporated into the system 100. A press must be sufficiently large to deform the workpiece through thickness. This dictates that the projected area must be similar to the thickness of the workpiece, and the press force significantly exceeds that of the flow stress of the material (usually by a factor of 2-5). Base calculations can be developed from classical slip-line or slab analysis theories.

[0047] While systems like additive and subtractive manufacturing often are rated to volume/time that can be added or removed, deformation processing, with appropriate power, can displace larger volumes per time. Retaining heat, quick motion from one forming location to another and high amounts of deformation power enable rapid deformation processing.

[0048] As the manufacturing method used by the system 100 may be based on re-shaping, there is no material loss in the primary operation. In machining, large material losses are routine and expressed in the buy-to-fly ratio. Similarly in powder-bed metallic additive manufacturing, only a fraction of atomized powder sizes is selected, reducing process material use efficiency. As this is basically a forging process, forged materials properties are expected and can be assured by appropriate process monitoring. This basic framework is easily adaptable by re-configuring the STARC elements described above.

[0049] It is essential to note that for each class, there are several possible ways to develop a metamorphic manufacturing system 100 that can accomplish the same basic needs of rough machining. One example configuration of the system 100 is shown in FIG. 7, and includes a press 701, a compliance device 703 (i.e., inspection means), an induction coil 705 (i.e., a heating means), a servoelectric actuator 707, and a sliding tool rack 709 (i.e., positioning means). We note that many features may be eliminated or added to the system 100. In particular, other means of deformation may be included such as a hammer or roller instead of the press 701. Other means for heating may be included such as flames or lasers instead of the induction coil 705. Other means for compliance 703 may be included such as optical or ultrasonic inspection means. Other means for numerical control and position may be used instead of the sliding tool rack 709 and servoelectric actuator 707. [0050] The compact, economical, and agile system 100 may include the servo electric actuator 707 which can move relatively quickly and measure force as well as displacement. Conventional load cells and displacement transducers, among other solutions, can be used to monitor press force and displacement. A suitable servo electric actuator 707 is from the vendor Promess. Other servo electric actuators 707 may be used. The sliding rack of tools 709 that can combine flat, convex, circular or linear punching tools on opposed sides. Tools 709 may be used for forming, cutting piercing, bending and so on. The tools 709 can be quickly changed by actuating stepper motors on either side. This change can take place in about one second or less. Straightening can take place by rotating about the rotational degree of freedom and sequentially squeezing between flats. The Promess system is particularly good as the press can give force and displacement measurements or control. In some embodiments, the press may operate in a downward manner and may include a flat plate as a primary lower tool. This configuration may allow gravity to keep a workpiece in a preferred location. The tool rack may use rotational motion instead of linear motion or may use a gang or turret system to hold multiple tools that can be inserted in a manner that is common in CNC (Computer Numerically Controlled) machining systems.

[0051] In some embodiments, the tool 709 may include one or more grips similar to blacksmith tongs. The grips allow for repeated re-positioning of a workpiece during manufacturing. Where grips are used the system 100 may further include optical shape recognition or motion capture to facilitate the griping and re-positioning.

[0052] Induction heating may be used as a heating component. This can include thermal feedback by thermocouples or optical means. One approach to heating is uniform heating to reach forming temperatures. We can also consider stress relief, and austenizing, quench and temper operations in steel. This can be carried out by heating to appropriate temperature and using a water spray for quenching and possibly using induction to temper. One important realization is that varied coils can be used for bulk or local heating, and these can be co-linear and adjacent to the punch. This minimizes time for motion and cooling. Automated means may be used to change coils. We also note that as samples become larger, time for cooling increases allowing much flexibility.

[0053] FIG. 8 shows an example configuration for system 100 which includes a Tormach CNC milling machine for positioning with the Stewart-Platform co pliance device and a servo electric press, which together allow motion of the workpiece relative to the press with the compliance device providing protection from overstressing the system 100. The other details of the system 100 are shown in the views of FIG. 8 (i.e., the views 801-817) . The images 801, 803, and 807 show the system 100 both with and without a protective cover. The images 805 and 815 show the workpiece being compressed by the servo electric press, also visible in 805 are several tools which may slide up and down to do work to the workpiece, these sliding tools are to the left and right of the workpiece. The images 809 and 813 depict induction heating of the workpiece in an area proximal to the servo press. The image 817 depicts use of the Tormach CNC mill's milling heat to perform 4 axis CNC machining operations on the workpiece. Additional aspects include optical scanning for component shape shown in the image 811. An additional vice or support can add rigidity for machining or other operations. We also note that this system 100 may be rotated such that the workpiece is hanging vertically. This can reduce bending moments.

[0054] FIG. 9 is an illustration of an example system 100 with an updated press and tool changer. As shown, there are several views in FIG. 9 showing different aspects of the system 100 (i.e., the views 901-905). Here the original welded structure is replaced with a more robust bolted design. FIG. 9 further shows updates to the design with a more mechanically predictable bolted press design. The FIG. 9 design is an improvement on the conceptual design shown in FIG. 8, and has been manufactured and has passed prototype testing.

[0055] FIG. 10 is an illustration of a system 100 including an add-on-kit 1003 for blacksmithing. In particular, the add-on-kit 1003 may be adapted to be added to any system that that includes a CNC milling machine. In the example shown, the CNC milling machine includes a 2-axis table 1001 that the add-on-kit 1003 is mounted to. The add-on-kit 1003 includes a 1^st rotary axis 1005 and 2^nd rotary axis 1007. The add-on-kit 1003 further includes a compliance device 1009 for interfacing with a workpiece 1011. A suitable compliance device 1009 includes the compliance devices described above. The add-on-kit 1003 allows the workpiece 1011 to interact with components of the system 100 such as the deformation tool 1015 and the heat source 1013.

[0056] Robotically assisted open die forging (Robotic Blacksmithing a subtype of metamorphic manufacturing) has been demonstrated with the use of a 6-axis robot arm as the primary method of manipulation. Forging is a process by which metal parts are formed by deformation at high temperatures, typically with metal dies which have negatives of the intended part carved into their surfaces. When the dies possess the form of the intended part the forging process is referred to as 'closed die forging'. Closed die forging is a mature manufacturing process requiring little additional automation; however, the dies can be expensive and this expense precludes prototypes and short production runs. Open die forging, an alternative to closed die forging, does not require dies which are custom made for each part. However, open die forging does require specialized manipulation of workpieces so that simple dies may apply a sequence of deformations which ultimately result in a part of similar complexity to an open die forged component.

[0057] The blacksmithing craft is an example of open die forging, where 3D manipulation of the workpiece is accomplished by the blacksmith. Robotically assisted open die forging ( robotic blacksmithing) aims to autonomously produce parts without the need for a skilled blacksmith or specialized and expensive dies. As mentioned previously, robotically assisted open die forging has been successfully demonstrated by the use of a 6-axis robot arm. The choice of a robot arm is appropriate under certain circumstances, however part manipulation 3D space can be accomplished with simpler and lower cost methods.

[0058] Robotic part production by subtractive manufacturing is commonly performed by 3 axis computer numerical controlled (CNC) milling machines. CNC milling machines typically include a high strength, high accuracy, positioning table with two translation axis (the tables on some mills have 3 translation axis). CNC milling machines are typically used for carving parts from solid material. Their tables have convenient slots for fixturing vises and other add on equipment. An aspect of the invention being disclosed here is a collection of add-on equipment (i.e., the add-on-kit 1003) for a CNC milling machine which will add up to 3 rotation axis and up to 1 translation axis (i.e., the axis 1005 and the axis 1007) to a standard CNC milling machine, additionally a tool for heating workpieces (i.e., the heat source 1013) to forging temperature, and a deformation tool (i.e., the deformation tool 1015) are included in this invention.

[0059] FIG. 10 depicts an add-on-kit 1003 for a CNC milling machine which consists of two rotary axis 1005 and 107 and one translation axis. These components take a milling machine's table which has only two degrees of translational freedom and adds an additional translation axis and two rotary axis, resulting in a machine capable of manipulating a workpiece with 5 degrees of freedom.

[0060] Also shown in FIG. 10 is a deformation tool 1015 (hydraulic press, servo press, pneumatic press, or hammer mechanism) which is essential to the utility of this add-on-kit

1003. A deformation tool 1015 of the typed mentioned above may be added proximate to the milling machine to allow for robotically controlled deformation of a workpiece. The addition of a deformation tool 1015 to a CNC milling machine is a component of this invention.

[0061] Also shown in FIG. 10 is a compliance mechanism and/or stress measurement system 1009 which is useful for the safe operation of this add-on-kit 1003. Stress from the deformation tool 1015 cannot be allowed to travel into the axis added to the milling machine, therefore a method for preventing stress from traveling is needed. A 6-degree load cell may be used in conjunction with a software program which allows the axes of the CNC mill and add on axis to move to minimize the strain imparted into the mechanical system by the deformation tool 1015. Another technique is to use a 6 degree of freedom compliance device. Such a compliance device must hold the workpiece rigidly until a set stress is reached, at which point the compliance device ceases to hold the workpiece rigidly.

[0062] A method for heating workpieces is also depicted in FIG. 10 (i.e., the heat source 1013) which is useful for this invention, but is not necessary. Methods for heating include but are not limited to a gas forge, laser light, reflected halogen light, an electric resistance furnace, an induction furnace, electric arcs, and direct electrical resistive heating. A heat source 1013 may be placed proximate to the CNC mill and within reach of the table and add on components.

[0063] FIG. 11 is an illustration of a method 1100 for operating the agility forge. The method 1100 may be executed by the computation component 105 of the system 100. The method 1100 may be the process through which the system 1100 generates a desired workpiece from an initial set of materials.

[0064] At 1101, a user provides a file 1105 that represents a desired workpiece. The file 1105 may be a "destination. obj" file and may specify the desired properties and geometries of the completed workpiece. The user may have initially created the file 1105 using a computer aided design application or may have selected the file from a library of files stored on the system 100.

[0065] In addition to the file 1105, a workpiece 3D scan 1107 may be received. The workpiece 3D scan may be a scan of the current state of the materials that have been selected for the desired workpiece. For example, the materials selected for the workpiece may be metal ingot, plastic cube, or any other shape or type of raw materials. The workpiece 3D scan 1107 may be captured using a vision or scanning component associated with the system 100 such as a 3D scanner, LIDAR device, or camera device. Any device capable of capturing a 3D representation of an object may be used.

[0066] At 1121, a process for creating an intermediate model is performed. Because the system 100 generates the workpiece using an iterative process, the intermediate model may represent an intermediate form that the workpiece should have at the end of the current iteration. The design of the intermediate model may be dependent on a variety of factors such as the material being using for the workpiece and capabilities of the system 100. There may be multiple intermediate models between the initial shape or volume of the workpiece and the desired final or destination geometry. An example process for creating the intermediate model is described by the method 1200 of FIG. 12. The intermediate model may be selected in part based on user input and preferences 1103.

[0067] At 1123, a process for selecting hit points is performed. The hit points as used herein may identify the locations on the workpiece that should be "hit" or worked on by a tool of the system 100. These locations are referred to as deformation points and may be informed based on the tool or tools that are available to be used by the system 100 on the workpiece. An example process for selecting the hit points is described by the method 1300 of FIG. 13. The hit points may be selected in part based on user input and preferences 1103. [0068] At 1125, one or more tools are selected. The one or more tools may be the tools that will be used to deform the workpiece. The system 100 may select from a variety of different tools such as flatting, rounding, hole punching, and indentation dies, other tools such as hammers of different size and shape, brushes, and rollers may also be used. As may be appreciated, each system 100 may have a different set of tools that are available to use. Tools may be selected by considering a variety of factors such as which does the most work, which tool provides the most stability, and which tool is most likely to result in a desired target shape An example process for selecting tools is described by the method 1400 of FIG. 14. The one or more tools may be selected in part based on user input and preferences 1103.

[0069] At 1127, hit point culling may be performed. An example process for hit point culling is described by the method 1500 of FIG. 15. Generated hit points may be culled for a variety of reasons, including duplication, little to no meaningful work expected with the selected tool, or because deformation at the culled hit point would be detrimental to the overall forging process. The hit points may be culled in part based on user input and preferences 1103.

[0070] At 1129, toolpath generation is performed. A toolpath as used herein may be an ordered sequence of tools and hit points that are to be applied to the workpiece to deform it to the intermediate model. The generated tool path may be generated based on the selected tools and while omitting any culled hit points. A tool path is series of waypoints and positions described in a language, like Geode for example, that a machine can interpret and follow to produce the intended deformations at the desired hit points with the specified tools.

[0071] At 1131, a forging process is performed. The forging process may be performed by the system 100 on the workpiece using the selected tools according to the generated toolpath. [0072] At 1133, a 3D scan of the workpiece is performed. The 3D scan may be used to update the workpiece 3D scan 1107 and may become the model for the intermediate workpiece. The method 1100 may then repeat until the workpiece matched the final workpiece as specified by the user at 1105.

[0073] FIG. 12 is an illustration of a method 1200 for intermediate model generation. The method 1200 may be executed by the computation component 105 of the system 100.

[0074] The method 1200 may begin with the receipt of the file 1105 describing the final or destination shape of the workpiece and the scan 1107 of the current workpiece. As may be appreciated, as each iteration of the method 1100 is performed, the scan 1107 of the workpiece is changed.

[0075] The file 1105 and the scan 1107 are then fed into one or more model generation functions. In the example shown, two model generation functions are shown, a generation function produced intermediate models via a linear constant volume transformation, here referred to as the Simple Intermediate Model Generator 1201 and a generation function called Finite Element Informed Intermediate Model Generator 1203. Other functions may be used as represented by the generator 1204. Depending on the embodiment, each generation function may further receive user preferences 1103 that may direct how each function is performed. Alternatively, rather than generating an intermediate model, the method 1200 may use an intermediate model generated by a previous iteration of the method 1200 as represented by the skip step 1205.

[0076] At 1209, in some embodiments, where multiple generation functions were used, a selection from among the generated models may be performed. The selection may be performed by the user as represented by the user choice 1207. The selected intermediate object is the "intermediate model. obj" and may be returned to the method 1100 by the method 1200 at the completion of the method 1200.

[0077] FIG. 13 is an illustration of a method 1300 for hit point selection. The method 1300 may be executed by the computation component 105 of the system 100. The method 1300 may begin with the receipt of the file 1105 describing the final or destination shape of the workpiece and the intermediate object 1107 generated by the method 1200. Also received is a file 1301 representing the shape of one or more forming tools that may be used by the system 100 to hit the workpiece.

[0078] The file 1105, intermediate object 1107, and the forming tool geometry 1301 are then fed into one or more hit point generation functions. In the example shown, two hit point generation functions are shown, a generation function called macro selected hit points 1304 and finite elements informed hit points 1305. Strain rate or temperature may be further modified to give better microstructural results in addition to shape-making. Depending on the embodiment, each hit point generation function may further receive user preferences 1103 that may direct how each function is performed. Alternatively, rather than generate the hit points, the user may select the hit points at 1303, or some other criteria may be used to select hit points at 1306.

[0079] At 1309, in some embodiments, where multiple hit point generation functions were used, a selection from among the generated hit points may be performed. The selection may be performed by the user as represented by the user choice 1307. The selected hit points may be a list of hit points, vectors and normals (1311) and may be returned to the method 1100 by the method 1300 at the completion of the method 1300.

[0080] FIG. 14 is an illustration of a method 1400 for tool selection. The method 1400 may be executed by the computation component 105 of the system 100. The method 1400 may begin with the receipt of the file 1105 describing the final or destination shape of the workpiece and the intermediate object 1107 generated by the method 1200. Also received is a file 1301 representing the shapes of a plurality of forming tools that may be used by the system 100 to hit the workpiece.

[0081] The file 1105, intermediate object 1107, and the forming tool geometries 1301 are then fed into one or more tool selection functions. Each function may consider different factors for selecting a tool to use for each hit point of the generated hit points 1311 generated by the method 1300. In the example shown, two selection functions are shown, a selection function called chosen by most work 1404 and a selection function called chosen by closest approach to the intermediate model 1405. The most work select function may select the tool that can deform the most material of the intermediate object 1107, while the closest approach model may select the tool that that gets the closest to the current hit point. Other methods for tool selection may be used as represented by the other selection criteria for tools 1406. In addition, in some embodiments, a user may select the tool for each of the hit points as represented by the user specified 1403. Each tool selection function may further receive user preferences 1103 that may direct how each selection function is performed.

[0082] Once the tools have been selected for each hit point, the method 1400 may return a list of hit points, vectors, and normals with a selected tool for each hit point (1407). The list may be same as the list 1311 returned by the method 1300, but with the addition of a tool selection for each hit point.

[0083] FIG. 15 is an illustration of a method 1500 for hit point culling method 1500 may be executed by the computation component 105 of the system 100. The method 1500 may begin with the receipt of the file 1105 describing the final or destination shape of the workpiece, the intermediate object 1107 generated by the method 1200, the geometries of the various available forming tools 1301, and the list of hit points, vectors, and normals with a selected tool for each hit point 1407.

[0084] At 1501, the method 1500 may remove duplicate or near duplicate hit points from the hit points 1407. A hit point may be a duplicate if it within a threshold distance of another hit point.

[0085] At 1503, the method 1500 may remove hit points with no or minimal associated deformation from the hit points 1407. A hit point may be removed if its associated deformation is less than a first threshold.

[0086] At 1505, the method 1500 may remove hit points with excess deformation from the hit points 1407. A hit point may be removed if its associated deformation is greater than a second threshold.

[0087] At 1507, the method 1500 may produce a revised list of hit points, vectors, and normals with a selected tool for each hit point 1407. The list 1407 may be the same list as was received but without the removed hit points.

[0088] With reference to FIG. 16, an exemplary system for implementing aspects described herein includes a computing device, such as computing device 1600. In its most basic configuration, computing device 1600 typically includes at least one processing unit 1602 and memory 1604. Depending on the exact configuration and type of computing device, memory 1604 may be volatile (such as random access memory (RAM)), non-volatile (such as read-only memory (ROM), flash memory, etc.), or some combination of the two. This most basic configuration is illustrated in FIG. 16 by dashed line 1606.

[0089] Computing device 1600 may have additional features/functionality. For example, computing device 1600 may include additional storage (removable and/or non-removable) includi ng, but not limited to, magnetic or optical disks or tape. Such additional storage is illustrated in FIG. 16 by removable storage 1608 and non-removable storage 1610.

[0090] Computing device 1600 typically includes a variety of computer readable media.

Computer readable media can be any available media that can be accessed by the device 1600 and includes both volatile and non-volatile media, removable and non-removable media.

[0091] Computer storage media include volatile and non-volatile, and removable and nonremovable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Memory 1604, removable storage 1608, and non-removable storage 1610 are all examples of computer storage media. Computer storage media include, but are not limited to, RAM, ROM, electrically erasable program read-only memory (EEPROM), flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by computing device 1600. Any such computer storage media may be part of computing device 1600.

[0092] Computing device 1600 may contain communication connection(s) 1612 that allow the device to communicate with other devices. Computing device 1600 may also have input device(s) 1614 such as a keyboard, mouse, pen, voice input device, touch input device, etc. Output device(s) 1616 such as a display, speakers, printer, etc. may also be included. All these devices are well known in the art and need not be discussed at length here.

[0093] It should be understood that the various techniques described herein may be implemented in connection with hardware components or software components or, where appropriate, with a combination of both. Illustrative types of hardware components that can be used include Field-programmable Gate Arrays (FPGAs), Application-specific Integrated Circu its (ASICs), Application-specific Standard Products (ASSPs), System-on-a-chip systems (SOCs), Complex Programmable Logic Devices (CPLDs), etc. The methods and apparatus of the presently disclosed subject matter, or certain aspects or portions thereof, may take the form of program code (i.e., instructions) embodied in tangible media, such as floppy diskettes, CD- ROMs, hard drives, or any other machine-readable storage medium where, when the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the presently disclosed subject matter.

[0094] Although exemplary implementations may refer to utilizing aspects of the presently disclosed subject matter in the context of one or more stand-alone computer systems, the subject matter is not so limited, but rather may be implemented in connection with any computing environment, such as a network or distributed computing environment. Still further, aspects of the presently disclosed subject matter may be implemented in or across a plurality of processing chips or devices, and storage may similarly be effected across a plurality of devices. Such devices might include personal computers, network servers, and handheld devices, for example.

[0095] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.

Claims

What is claimed:

1. A system for manufacturing comprising: at least one computing device; and one or more forming actuators mounted on a CNC mill or lathe, wherein the CNC mill or lathe comprises: a heater; a tool contact area; a protective compliance mechanism; a machining head; and a plurality of rapidly changeable tools for deforming a workpiece into a desired shape according to a manufacturing process.

2. The system of claim 1, wherein the heater comprises an induction heater and comprises multiple coils that can be automatically changed such that only small displacement of the workpiece is required to change from heating to forming.

3. The system of claim 1, wherein the one or more forming actuators comprise one or more of a press, a hammer, or a roller.

4. The system of claim 1, further comprising a shape determination element for determining a current shape of the workpiece comprising one or more of a dimensional scanner, a camera, a thermal camera, or a LIDAR or other inspection component.

5. The system of claim 1, wherein the at least one computing device is adapted to monitor the progress of the workpiece being manufactured by the system according to the manufacturing process and to make one or more adjustments to the manufacturing process based on the monitoring.

6. The system of claim 1, wherein the system operates in a controlled atmosphere to avoid oxidation.

7. The system of claim 1, further comprising an air and/or water spray component that allows for freedom in thermomechanical processing including quenching and tempering.

8. The system of claim 1, further comprising a vice, wherein the vice is automated or manual.

9. The system of claim 1, wherein the system is configured to operate on a workpiece, wherein the workpiece may hang either vertically or horizontally and may be placed on the working surface of a press or an anvil.

10. The system of claim 1, wherein the one or more forming actuators generate force and displacement signals which are used by the at least one computing device to control the components of the system to deform the workpiece to a desired shape.

11. The system of claim 1, wherein the system further comprises an additive manufacturing component.

12. The system of claim 8, wherein the additive manufacturing component uses wire-arc.

13. A system for metamorphic manufacturing comprising: an enclosure; a plurality of sensors for monitoring a workpiece; a plurality of actuators for deforming the workpiece; a thermal component for heating the workpiece; a positioning component for positioning the workpiece; a software component for performing a method of metamorphic manufacturing of the workpiece; and one or more computing devices for receiving data from the plurality of sensors and for controlling the plurality of sensors, the plurality of actuators, the thermal component, and the positioning component to facilitate the method of manufacturing of the workpiece.

14. The system of claim 13, further comprising a compliance component, where the compliance component is a Stewart Platform or other multi degree of freedom device.

15. The system of claim 13, wherein the compliance component comprises a helical coil spring-based or pneumatic spring-based compliance device.

16. The system of claim 13, wherein the positioning component comprises a forklift.

17. The system of claim 13, wherein the plurality of actuators comprise one or more of a press, a hammer, or a roller.

18. The system of claim 13, wherein the method of metamorphic manufacturing comprises transforming a stock workpiece 3D model into a series of intermediate 3D models or waypoints between the stock workpiece 3D model and a given destination 3D model.

19. The system of claim 18, wherein the method of metamorphic manufacturing further comprises finite element or other simulation methods for predicting the outcome of incremental deformations applied to the workpiece, where the outcome includes the 3D shape of the workpiece after deformation as well as the microstructure and mechanical properties after deformation.

20. The system of claim 19, wherein the method of metamorphic manufacturing further comprises generating a series of deformation hit points for the workpiece.