Adaptive Cooling Control for Additive Manufacturing Workpieces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additive manufacturing processes face challenges in controlling heating and cooling, leading to inconsistent physical, thermal, and mechanical properties in workpieces due to uncontrolled spatial variations, which can result in distortion and affect the quality of additively manufactured parts.
Innovation Solution
A method and apparatus for controlled cooling of workpieces during additive manufacturing, utilizing a deposition head, a cooling subsystem, and a controller to measure thermal characteristics and adjust coolant flow rates and temperatures based on predetermined thresholds, ensuring consistent thermal history and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uncontrolled heating and cooling is applied during additive manufacturing, then the manufacturing process is simple and fast, but the physical, thermal, and mechanical properties of the workpiece become inconsistent
Solution Approach 1:
The patent applies local quality by implementing region-specific cooling parameters. Different regions of the workpiece receive customized cooling treatments based on their thermal characteristics, material composition, and geometric features. The controller adjusts cooling parameters (flow rate, temperature, duration) for each region independently, ensuring optimal cooling that maintains consistent material properties throughout the workpiece while accounting for local variations.
Solution Approach 2:
The patent implements dynamics by making the cooling parameters adaptive and variable during the manufacturing process. The system continuously monitors thermal characteristics and dynamically adjusts cooling parameters in real-time based on feedback from sensors and thermal models. This dynamic adjustment allows the cooling system to respond to changing thermal conditions throughout the additive manufacturing process, maintaining property consistency.
2Productivity
If rapid cooling is applied to increase productivity, then the manufacturing speed increases, but thermal residual stresses and distortion increase
Solution Approach 1:
The patent applies preliminary action by using thermal modeling and simulation before the actual additive manufacturing process. The system predicts thermal characteristics, cooling rates, and potential stress zones in advance. Based on these predictions, the controller pre-configures appropriate cooling parameters to prevent excessive thermal gradients and residual stresses, allowing rapid cooling without compromising workpiece integrity or increasing distortion.
Solution Approach 2:
The patent implements feedback by continuously monitoring thermal characteristics during the manufacturing process and using this information to adjust cooling parameters. Sensors measure temperature distributions and thermal gradients in real-time, and the controller modifies cooling rates based on this feedback to maintain thermal stresses within acceptable limits while preserving high manufacturing speed.
3Manufacturing precision
If uniform cooling is applied to all regions, then the cooling process is simple to control, but spatially variable heating and cooling effects cannot be compensated
Solution Approach 1:
The patent applies segmentation by dividing the workpiece into multiple regions with distinct thermal characteristics. Each region is assigned specific cooling parameters based on its material composition, geometry, and thermal behavior. The cooling system independently controls each region, allowing precise compensation for spatially variable heating effects while maintaining manageable operational complexity through automated regional management.
Solution Approach 2:
The patent implements parameter changes by varying cooling parameters (temperature, flow rate, duration, application timing) across different regions and throughout the manufacturing process. The controller automatically adjusts these parameters based on thermal models and real-time measurements, enabling precise control over thermal history in each region without requiring complex manual intervention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for tailored mechanical properties, reduced defects, consistent deposition layers, and predictable microstructure, potentially eliminating the need for post-deposition treatments and reducing inspection and machining costs.
Implementation Method 1
cooling the workpiece... determining a thermal characteristic of a portion of the workpiece... responsive to determining that the thermal characteristic of the portion exceeds a threshold associated with the portion, a cooling parameter of a cooling flow to be applied to the workpiece is adjusted
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method (700) for use in additive manufacturing of a three-dimensional workpiece (30) is described. The method includes depositing material (M) onto a substrate (28) to form a shape of the workpiece (30) in accordance with an additive manufacturing process; determining a thermal characteristic (40) of at least a portion (42) of the workpiece (30) during the additive manufacturing process; determining that the thermal characteristic (40) of at least the portion (42) exceeds a threshold (50) associated with the portion (42); adjusting a cooling parameter of a cooling flow (C) to be applied to the workpiece (30) responsive to determining that the thermal characteristic (40) of at least the portion (42) exceeds the threshold (50) associated with the portion (42); and applying the cooling flow (C) with the adjusted cooling parameter to at least the portion (42) of the workpiece (30).