Additive Bead Routing for Uniform Temperature and Shape Accuracy
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Solution Overview
Problem
The existing additive manufacturing methods, such as those described in Japanese patent No. 4551082, face challenges in achieving shape accuracy due to temperature differences between laminated bodies formed under different conditions, leading to variations in shape and height.
Innovation Solution
The proposed method involves forming linear beads in a predetermined sequence and gap configuration to maintain consistent formation conditions, ensuring that each bead is parallel to its predecessor with a controlled gap, which helps in minimizing temperature variations and improving shape accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the entire first laminated body is formed before forming the second laminated body, then the manufacturing process can be completed in sequence, but significant temperature differences occur between target surfaces leading to large variations in shape and height
Solution Approach 1:
The manufacturing process is segmented into multiple passes where not all laminated bodies are completed in one pass. Instead, the process alternates between forming odd-numbered and even-numbered laminated bodies across multiple passes, ensuring temperature uniformity across target surfaces during each pass while maintaining overall productivity through systematic progression.
Solution Approach 2:
The manufacturing process uses periodic action by alternating between forming odd-numbered laminated bodies in one pass and even-numbered laminated bodies in subsequent passes. This periodic formulation approach ensures that temperature conditions remain uniform across target surfaces during each formulation pass, thereby improving shape accuracy while maintaining manufacturing efficiency.
2Productivity
If multiple laminated bodies are formed under different temperature conditions, then the manufacturing process can proceed efficiently, but variations in temperature cause differences in shape and height of the laminated bodies
Solution Approach 1:
The set of laminated bodies is segmented into odd-numbered and even-numbered groups that are formed in separate passes under different temperature conditions. By form only odd-numbered laminated bodies in one pass and even-numbered ones in subsequent passes, the process ensures uniform temperature distribution across target surfaces during each pass, thereby maintaining shape uniformity while preserving manufacturing efficiency.
Solution Approach 2:
Different target surfaces receive tailored formulation conditions based on their position (odd or even numbered). Each target surface is formulated under temperature conditions appropriate for its specific position in the sequence, ensuring that local temperature uniformity is maintained across all target surfaces during each pass, which results in uniform shape and height across all laminated bodies.
3Ease of operation
If the same formation conditions are applied to all laminated bodies regardless of temperature, then the process is simple to control, but significant temperature differences result in large variations in shape and height
Solution Approach 1:
The process control uses periodic action by alternating between forming odd-numbered and even-numbered laminated bodies in separate passes. This systematic alternation maintains relatively uniform temperature conditions across target surfaces during each pass while keeping the control logic simple and repeatable, thereby achieving both ease of operation and manufacturing precision.
Solution Approach 2:
The process control changes the formulation sequence parameter systematically by alternating between odd and even numbered laminated bodies across passes. This parameter change strategy ensures that each target surface is formulated under appropriate temperature conditions for its position, maintaining shape and height consistency while preserving simple and systematic process control.
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 enhances the shape accuracy of manufactured objects by maintaining uniform temperature conditions and reducing unevenness between beads, thereby improving the overall flatness and accuracy of the final product.
Implementation Method 1
forming a first linear bead and a second linear bead parallel to each other... forming a third linear bead in the gap... by laminating a linear bead on a target surface
Implementation Method 2
additive manufacturing method for manufacturing a three-dimensional object by laminating a linear bead on a target surface
Data Source
Figure 1
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AI summary
An additive manufacturing method includes: a step of forming a first linear bead and a second linear bead parallel to each other under a same predetermined formation condition such that a gap having a predetermined width is formed between the first linear bead and the second linear bead; and a step of forming a third linear bead in the gap under the same formation condition. Moreover, the additive manufacturing method includes: a step of forming, after forming the third linear bead, the linear bead that is formed as an even-numbered line under the formation condition such that the linear bead is parallel to the first linear bead and a gap having a predetermined width is formed between the linear bead formed as an even-numbered line and a linear bead formed two lines before; and a step of forming, after forming the third linear bead, the linear bead that is formed as an odd-numbered line in the gap between the linear bead formed immediately before and the linear bead formed three lines before under the formation condition.