A D V A N C E D M A T E R I A L S & P R O C E S S E S | J A N U A R Y / F E B R U A R Y 2 0 2 3 2 8 Fig. 3 — Hybrid autonomous manufacturing. HAMMER – Hybrid Autonomous Manufacturing: Moving from Evolution to Revolution Prof. Glenn Daehn The Ohio State University The modern engineer must think both in terms of bits and atoms. Digital design and manufacturing are now the mainstream expectation. Computer numerical control (CNC) machining was the first step in this journey, and the same basic path planning and 3D rendering has been used to support additive manufacturing (AM). There is now much focus on optimizing the materials that are produced by additive manufacturing, as well as collecting data to sense possible defect locations, and expanding the library of available materials. Both CNC machining and additive manufacturing are methods that are primarily for shape making. Plastic deformation is the other obvious way to make shapes – and thermomechanical processing, which also involves deformation, is our community’s standard tool for improving materials properties. One point raised during this session is that we should have a digital analog for making shapes via deformation as we have for CNC machining and additive manufacturing. Such a tool could resemble a robotic blacksmith. This automaton could at once both create target shapes by deformation and improve microstructure—as the human blacksmith does. Deformation processing also generally has a much lower embodied energy per mass than the creation of parts by additive or subtractive processing. Another advantage of deformation is it scales to large sizes with commercially available robots and presses, enabling the creation of parts orders of magnitude larger than a human could manufacture. This approach has been developed and written in a Metamorphic Manufacturing report (available at tms.org/metamorphicmanufacturing)[6]. In recent months, a team of researchers from Ohio State (led by Daehn), Northwestern University (Jian Cao, leader), Case Western Reserve University (John Lewandowski, leader), University of Tennessee Knoxville (Tony Schmitz, leader), and North Carolina Agricultural and Technical University (Jag Sankar, leader) went deeper into the basic ideas of how we manufacture structural components and came to realize that addition, subtraction, deformation, transformation, inspection, and positioning represent the universe of basic operations that are executed to develop manufacturing processes and all can be done incrementally, usually with simple equipment. We can break these operations down and reassemble these like code and subroutines. This is at the heart of a newly funded NSF Engineering Research Center HAMMER: Hybrid Autonomous Manufacturing— Moving from Evolution to Revolution (see hammer.osu.edu). We envision a future of manufacturing for design, where for example, a preform could be created by inexpensive high-throughput processes such as wire-arc additive manufacturing of a multimaterial preform or by welding similar or dissimilar metallic volumes and then use thermomechanical precision open-die forging processing to fabricate a nearnet shape with tailored local properties. Critical dimensions could be Beuth Daehn Furrer Maher Fig. 2 — Panel members, Advanced Manufacturing: Progress and Opportunities. Frazier
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