TECHNICAL FIELD

[0001] The present disclosure is directed to the field of manufacturing, more particular to additive manufacturing.

BACKGROUND

[0002] Typical machining requires material to be removed from a workpiece. Various techniques may be used for machining. For example, machining may be done by way of electrical methods such as electrical discharge machining (EDM) or electro mechanical machining (ECM). Both EDM and ECM remove material via electricity and a fluid medium, dielectric for EDM and conducive for ECM. Numerous mechanical methods may be employed. Broaching and hobbing similar in which they both use a cutting tool, broach and hob respectively, to cut material away from the workpiece. Other mechanical methods may include sanding or planning to remove material. Laser may be, using a laser to melt, burn or vaporize material on the work piece may be used.

[0003] FIG. 1 illustrates an example of machining 10 via a cutting tool 11 of a workpiece 12. The removal of the material, by typical machining techniques, is ordinarily wasteful. It may be a time c

[0004] The removal of material by typical machining may be time intensive to form an object from the workpiece, especially more complex objects and/or objects needing accurate formation.

[0005] Manufacturing systems and method may benefit from improvements.

SUMMARY

[0006] Variously disclosed embodiments include systems and methods that may be used to facilitate additive manufacturing according to embodiments of the present invention. In one example, an additive manufacturing method is provided. The method includes forming a monolithic structure on a build plate. The formed monolithic structure includes a first tooth wheel and second toothed wheel. The forming is by way of a material deposit head, which adds material, and which is controlled by a processor. Subsequent to the forming, the monolithic structure is removed from the build plate.

[0007] In another example, an additive manufacturing system is provided according to an embodiment. The system includes a build plate, a material deposit head, and a processor. The material deposit adds material to the build plate. The processor controls the movement of the material deposit head and the deposition of material by the material deposit head. Wherein a monolithic structure is formed orthogonally on the build plate. The monolithic structure includes a plurality of toothed wheels.

[0008] The foregoing has outlined rather broadly the technical features of the present disclosure so that those skilled in the art may better understand the detailed description that follows. Additional features and advantages of the disclosure will be described hereinafter that form the subject of the claims. Those skilled in the art will appreciate that they may readily use the conception and the specific embodiments disclosed as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. Those skilled in the art will also realize that such equivalent constructions do not depart from the spirit and scope of the disclosure in its broadest form.

[0009] Also, before undertaking the Detailed Description below, it should be understood that various definitions for certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases. While some terms may include a wide variety of embodiments, the appended claims may expressly limit these terms to specific embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 illustrates an example of mechanical machining via a cutting tool of a workpiece according to the prior art.

[0011] FIG. 2 and FIG. 3 illustrates a perspective views of embodiments of toothed wheels.

[0012] FIG. 4 illustrates a schematic of an exemplary additive manufacturing system 50 according to an embodiment. [0013] FIG. 5 illustrates an exemplary monolithic structure 60 formed on the build plate 52 according to an embodiment.

DETAILED DESCRIPTION

[0014] Various technologies that pertain to systems and methods that facilitate additive manufacturing will now be described with reference to the drawings, where like reference numerals represent like elements throughout. The drawings discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged apparatus. It is to be understood that functionality that is described as being carried out by certain system elements may be performed by multiple elements. Similarly, for instance, an element may be configured to perform functionality that is described as being carried out by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

[0015] Additive manufacturing (AM) describes the technologies that build 3D objects by adding layer-upon-layer of material, regardless of the type of material. AM equipment lays successive layers of material in a layer-upon-layer fashion to fabricate a 3D object. For example, the technologies may include 3D Printing, Rapid Prototyping (RP), Direct Digital Manufacturing (DDM), layered manufacturing and additive fabrication.

[0016] FIGs. 2-3 shows a perspective view of toothed wheels 20 according to various embodiments. A tooth wheel is defined herein as an annular object with extending members. For example, a gear, fir tree disc or phonic wheel. The toothed wheel 20 comprises a root circle 23 formed around axis A. Teeth 26, in the singular tooth, extend from the root circle 23 and are space apart by gaps 25. The toothed wheel 20 has front face 27 and a back face 28. A depth 19 of the toothed wheel 20 is defined as an axial length of the toothed wheel 20. For example, a distance between the front face 27 and the back face 28.

[0017] The toothed wheel 20 of FIG. 2 illustrates a gear 21. While FIG. 2 illustrates an axial gear comprising teeth extending radially outward from the root circle 23 and extends along axis A, this is merely for illustrative purposes and not to limit the type of gear. It would be understood that alternative teeth design and/or gap formation may occur on the gear 21. For example, a helical gear may be formed with the teeth oblique to the axis or an internal gear formed with the teeth on the inner surface.

[0018] FIG. 3 shows a perspective view of an exemplary toothed wheel 20 embodied as a fir tree disc 31. A fir tree disc 31 is type of disc mount used in power generation. Teeth 26, resembling an inverted fir tree extend from the root circle 14.

[0019] FIG. 4 illustrates a schematic of an exemplary additive manufacturing system 50 according to an embodiment. The system includes a build plate 52, a material deposit head 54 and a processor 56. The processor 56 controls the movement of the material deposit head 54 and the deposition of a material by the material deposit head 54. The material is deposited to form a monolithic structure, which comprises a plurality of toothed wheels.

[0020] FIG. 5 illustrates an exemplary monolithic structure 60 formed on the build plate 52 according to an embodiment. The plurality of toothed wheels 20 are formed as a monolithic structure 60. Adjacent toothed wheels are adjoined and attached to one another. The monolithic structure has a depth 69 which is at least the sum of the depth 19 of each of the toothed wheels 20 of the monolithic structure 60. In one embodiment, each of the toothed wheels formed as the monolithic structure 60 comprises the same depth. In an alternative embodiment, at least one of the toothed wheels formed as the monolithic structure comprises a depth different than the remaining toothed wheels.

[0021] According to an embodiment, the monolithic structure 60 is formed orthogonal to the build plate 52. The monolithic structure 60 is removed from the build plate after the formation.

[0022] The monolithic structure 60 may be separated into individual toothed wheels 20. The separation may be performed at any time prior to using one of the toothed wheels 20. A separation of the toothed wheels 20 from the monolithic structure 60 may include at least one machining process. The machining process may be, for example, base on electrical machining, mechanical machining or laser machining. The separation removes one or more toothed wheels 20 from the monolithic structure 60.

[0023] Additive manufacturing process can provide a high accuracy of the formation of the toothed wheel 10. A small amount of excess material could be formed during the additive manufacturing. Any excess material may be removed. The removal may be by any machining process. For example, a machining may be performed to obtain a desired tooth tolerance. In an embodiment, the machining for the tooth tolerance is after the separation. In an alternative embodiment, the machining for the tooth tolerance is prior to the separation.

[0024] In an embodiment, a machining may be performed to smooth at least one of the faces 24, 28 of the toothed wheel 20 after the separation. The operation of smoothing may be performed with or without a removal of excess material.

[0025] A monolithic structure 60 would not have been performed by traditional machining. Machining would have taken too long to produce the monolithic structure. In addition to the possibility of reducing waste and reducing manufacturing time, a toothed wheel 20 may be more uniformly produced from a monolithic structure 60.

[0026] The additive manufacturing system and method have been described above using toothed wheels as the object manufactured. It would be understood that other objects may be manufactured in a monolithic structure without deviated from the system and methodology described above.

[0027] The machining techniques listed herein are merely examples and not an exhaustive list. It would be understood that other machining techniques to remove material may be used.

[0028] Also, it should be understood that the words or phrases used herein should be construed broadly, unless expressly limited in some examples. For example, the terms “include” and“comprise,” as well as derivatives thereof, mean inclusion without limitation. The singular forms“a”,“an” and“the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, the term“and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. The term“or” is inclusive, meaning and/or, unless the context clearly indicates otherwise. The phrases“associated with” and“associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.

[0029] Also, although the terms "first", "second", "third" and so forth may be used herein to refer to various elements, information, functions, or acts, these elements, information, functions, or acts should not be limited by these terms. Rather these numeral adjectives are used to distinguish different elements, information, functions or acts from each other. For example, a first element, information, function, or act could be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act could be termed a first element, information, function, or act, without departing from the scope of the present disclosure.

[0030] In addition, the phrase“based on” is intended to mean“based, at least in part, on” unless explicitly stated otherwise.

[0031] Although an exemplary embodiment of the present disclosure has been described in detail, those skilled in the art will understand that various changes, substitutions, variations, and improvements disclosed herein may be made without departing from the spirit and scope of the disclosure in its broadest form.

[0032] None of the description in the present application should be read as implying that any particular element, step, act, or function is an essential element, which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Moreover, none of these claims are intended to invoke a means plus function claim construction unless the exact words "means for" are followed by a participle.