Method for producing mechanical parts from an assembly of layers which are turned over during machining, and the elemental laminations and assembled parts produced

• US 6,745,446 B1
• Filed: 08/21/2001
• Issued: 06/08/2004
• Est. Priority Date: 11/19/1998
• Status: Expired due to Term

• Current Assignee: C.I.R.T.E.S.
• Original Assignee: C.I.R.T.E.S. (Centre D'Ingenierie De Recherche Et De Transfert De L'Esstin A Saint-Die)
• Inventors: Barlier, Claude
• Primary Examiner(s): Olms, Douglas
• Assistant Examiner(s): Blount, Steven
• Application Number:
  US09/856,208
• Time in Patent Office: 1,022 Days
• Field of Search: 294/12, 294/15, 294/17, 294/18, 700/197, 700/163, 700/119
• US Class Current: 29/412
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 29/49789 Obtaining plural product pieces from unitary workpiece
• CPC Class Codes: Y10T 29/49799 Providing transitory integral holding or handling portion

Abstract

Mechanical parts and other objects are produced from a specific computer-assisted design by successive steps including producing pieces of the part or object in elementary layers or strata, building up the collection of layers, and assembling the layers. The layers are derived from previous decomposition of the part or object along specific planes, and one or several steps. At least a portion of one of the layers is turned over (by 180°) after one of its surfaces has been machined, and another surface is machined after the layer has been turned over.

Claims

1. A method for producing a mechanical part, including prototype parts, from a specific computer-aided design, comprising the steps of:

manufacturing the part as a plurality of elemental layers, wherein the elemental layers are defined by prior breakdown of the part along a plurality of planes, and wherein the plurality of elemental layers includes a machined layer;

machining first surface portions of the machined layer, forming holding areas during the machining of the first surface portions;

turning over the machined layer, through 180°

, after the first surface portions have been machined;

machining second surface portions after the turning over of the machined layer, thereby making the second surface portions easier to machine after the machined layer has been turned over, and eliminating the holding areas formed during the machining of the first surface portions by the machining of the second surface portions, thereby completely freeing the machined layer for subsequent assembly of the part;

building up the plurality of elemental layers, including the machined layer; and

assembling the built up plurality of layers to produce the part.

2. The method of claim 1 which further includes the steps of:

cutting the machined layer into two portions along a cutting plane;

separately machining each, of the portions; and

assembling the separately machined portions along the cutting plane.

3. The method of claim 2 wherein the cutting plane is substantially vertical.

4. The method of claim 1 wherein one of the plurality of elemental layers forms a section having surface portions which cannot be machined from a top or a bottom of the section, and which further includes the steps of:

separating the section into a plurality of sub-layers so that each of the sub-layers can be machined from the top or the bottom, wherein the plurality of sub-layers includes a machined sub-layer; and

machining first surface portions of the machined sub-layer, turning over the machined sub-layer, and machining second surface portions of the machined sub-layer after the turning over of the machined sub-layer.

5. The method of claim 1 wherein the assembly step further includes the step of positioning the plurality of layers for producing the part using an apparatus for assembly of the part.

6. An elemental lamination for producing a mechanical part, including prototype parts, which is manufactured as a plurality of elemental layers, wherein the elemental layers are defined by prior breakdown of the part along a plurality of planes, wherein the plurality of elemental layers includes the lamination, and wherein the lamination is produced by a method comprising the steps of:

machining first surface portions of the lamination, forming holding areas during the machining of the first surface portions;

turning over the lamination, through 180°

, after the first surface portions have been machined;

machining second surface portions after the turning over of the lamination, thereby making the second surface portions easier to machine after the lamination has been turned over, and eliminating the holding areas formed during the machining of the first surface portions by the machining of the second surface portions, thereby completely freeing the lamination for subsequent assembly of the part;

building up the plurality of elemental layers, including the lamination; and

assembling the built up plurality of layers to produce the part.

7. The elemental lamination of claim 6 which is produced by a method which further includes the steps of:

cutting the lamination into two portions along a cutting plane;

separately machining each of the portions; and

assembling the separately machined portions along the cutting plane.

8. The elemental lamination of claim 7 wherein the cutting plane is substantially vertical.

9. The elemental lamination of claim 6 wherein one of the plurality of elemental layers forms a section having surface portions which cannot be machined from a top or a bottom of the section, and which is produced by a method which further includes the steps of:

separating the section into a plurality of sub-layers so that each of the sub-layers can be machined from the top or the bottom, wherein the plurality of sub-layers includes a machined sub-layer; and

machining first surface portions of the machined sub-layer, turning over the machined sub-layer, and machining second surface portions of the machined sub-layer after the turning over of the machined sub-layer.

10. The elemental lamination of claim 6 which is produced by a method wherein the assembly step further includes the step of positioning the plurality of layers for producing the part using an apparatus for assembly of the part.

11. A mechanical part, including prototype parts, which is comprised of an assembly of manufactured laminations, wherein the laminations are defined by prior breakdown of the part along a plurality of planes, and wherein the assembly of laminations includes a machined lamination produced by a method comprising the steps of:

machining first surface portions of the machined lamination, forming holding areas during the machining of the first surface portions;

turning over the machined lamination, through 180°

, after the first surface portions have been machined;

machining second surface portions after the turning over of the machined lamination, thereby making the second surface portions easier to machine after the machined lamination has been turned over, and eliminating the holding areas formed during the machining of the first surface portions by the machining of the second surface portions, thereby completely freeing the machined lamination for subsequent assembly of the part;

building up the assembly of laminations, including the machined lamination; and

assembling the built up assembly of laminations to produce the part.

12. The mechanical part of claim 11 wherein the machined lamination is produced by a method which further includes the steps of:

cutting the machined lamination into two portions along a cutting plane;

separately machining each of the portions; and

assembling the separately machined portions along the cutting plane.

13. The mechanical part of claim 12 wherein the cutting plane is substantially vertical.

14. The mechanical part of claim 11 wherein one of the assembly of laminations forms a section having surface portions which cannot be machined from a top or a bottom of the section, and which is produced by a method which further includes the steps of:

separating the section into a plurality of sub-layers so that each of the sub-layers can be machined from the top or the bottom, wherein the plurality of sub-layers includes a machined sub-layer; and

machining first surface portions of the machined sub-layer, turning over the machined sub-layer, and machining second surface portions of the machined sub-layer after the turning over of the machined sub-layer.

15. The mechanical part of claim 11 wherein the machined lamination is produced by a method wherein the assembly step further includes the step of positioning the assembly of laminations for producing the part using an apparatus for assembly of the part.