A Systematic Design Methodology for Reconfigurable Machine Tools and Controllers for use with Hybrid Manufacturing Processes

Hybrid manufacturing processes, namely combining multiple processes to interact with the workpiece and each other, have the potential to overcome existing limitations, such as tool accessibility in CNC machining. The synergistic combination of multiple manufacturing processes may greatly benefit from retaining the ability to reconfigure the machine tool. Also, the use of modular control system architectures may provide robust and flexible control over a variety of operating conditions. Although systematic design tools exist to identify hybrid manufacturing processes, there are currently no structured frameworks that may be used to design and validate reconfigurable machine tool and open-architecture control system concepts. This paper seeks to define such a framework, whereby design constraints and requirements may be captured and later used to inform the design process. This paper describes the proposed method, in detail, and provides some illustrative examples of its application in the design of a parallel kinematic reconfigurable machine tool, for use with hybrid manufacturing processes.