Additive Manufacturing Bead Modeling for Accurate Shape Reproduction
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in accurately reproducing the shape of additively-manufactured objects due to factors like molten metal dripping and uneven heat input, leading to complex calculations and unrealistic deposition planning times.
Innovation Solution
The method involves dividing three-dimensional shape data into trapezoidal bead models with specific vertex rotations and overlapping portions to simplify calculation and enhance reproducibility, using an additive manufacturing device with a controller to adjust bead models based on three-dimensional shape data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex calculations are performed to finely adjust bead model shapes based on formation conditions, then manufacturing precision is improved, but calculation complexity increases and productivity decreases
Solution Approach 1:
The bead model is segmented into a standard portion (common to all beads) and a non-standard portion (specific to each bead's position and conditions). This segmentation allows the system to handle only the variable non-standard portions through simple calculations, while the standard portion remains unchanged, thus improving manufacturing precision without significantly increasing calculation complexity.
Solution Approach 2:
The standard portion of the bead model is predetermined and prepared in advance based on typical formation conditions. This preliminary action eliminates the need to recalculate the entire bead model for each deposition, reducing calculation time while maintaining shape accuracy through the adjusted non-standard portions.
2Manufacturing precision
If complex calculations are performed to finely adjust bead model shapes, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The bead model calculation is divided into a standard portion that requires no complex calculation and a non-standard portion that uses simple adjustment calculations. This segmentation simplifies the overall device complexity while maintaining the ability to achieve high manufacturing precision through targeted adjustments of the nonstandard portions.
Solution Approach 2:
Instead of performing complex calculations to determine entire bead shapes, the system changes parameters of the nonstandard portions (such as position, size, or shape modifiers) relative to the standard portion. This parameter-based approach reduces computational complexity while achieving the desired shape accuracy.
3Productivity
If uniform bead models are used for all layers, then productivity is improved, but manufacturing precision deteriorates due to shape deviations
Solution Approach 1:
The bead model structure implements local quality by having a standard portion that applies universally and nonstandard portions that are customized for each specific bead's location and conditions. This allows the system to maintain high productivity through the reusable standard portion while achieving high shape reproducibility through the localized adjustments in nonstandard portions.
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 simple and efficient adjustment of bead models, enabling high-reproducibility in creating target shapes with improved accuracy and reduced calculation complexity.
Implementation Method 1
weld beads being formed by melting and solidifying a filler material
Implementation Method 2
weld beads being formed by melting and solidifying a filler material
Implementation Method 3
accumulation of heat input
Data Source
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AI summary
This additive manufacturing method includes a step for dividing a three-dimensional model form into a plurality of layers, and dividing each of the divided layers into a plurality of bead models. A trapezoidal bead model has four vertices. In the step of dividing the layers into bead models, later-formed bead models adjoining earlier-formed bead models are arranged so as to have an area of overlap with the earlier-formed bead models. Further, of the vertices at either end of the bottom segment of the later-formed bead models, with the vertex on the side farther from the area of overlap as the center point, the other three vertices except for the center point are each rotationally shifted, altering the form of the trapezoidal bead models.