Additive Manufacturing Vibration Analysis for Internal Defect Detection
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Solution Overview
Problem
Existing coordinate measuring machines are inadequate for detecting internal defects and material properties in objects produced by additive manufacturing, such as cracks, fractures, and material stresses, which are critical for ensuring structural integrity and quality.
Innovation Solution
A method utilizing modal analysis and resonance testing to determine the dynamic behavior of additively manufactured components, comparing measured vibration behavior with simulated reference data to assess manufacturing quality and detect internal defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If coordinate measuring machines are used to measure the surface geometry of additively manufactured objects, then measurement precision is improved, but the ability to detect internal defects and material properties deteriorates
Solution Approach 1:
The patent applies mechanical vibration through modal analysis to excite the additively manufactured object and measure its dynamic response. By analyzing vibration modes and natural frequencies, the system detects internal defects such as cracks, pores, and material inconsistencies that cannot be observed through surface geometry measurement alone, thereby recovering the lost internal information while maintaining surface measurement precision.
2Manufacturing precision
If traditional manufacturing methods are used, then geometric manufacturing tolerances are easier to control, but internal object properties such as material density and structural integrity become increasingly difficult to ensure
Solution Approach 1:
The patent implements feedback by using modal analysis measurements to assess internal object properties and provide information about material density, structural integrity, and manufacturing defects. This feedback loop enables adjustment and optimization of additive manufacturing parameters to ensure consistent internal properties while maintaining geometric tolerances, thereby improving reliability without sacrificing manufacturing precision.
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
Enables the detection of internal defects and material properties in additively manufactured objects, providing a comprehensive assessment of manufacturing quality and ensuring structural integrity.
Implementation Method 1
measuring a frequency-dependent natural vibration behavior of the object produced by additive manufacturing by dynamically mechanically exciting the object
Implementation Method 2
detecting a body vibration generated in the object as a result of the excitation
Data Source
Figure 1~2a
Figure 2b~3b
Figure 4a~4b
AI summary
Method for object analysis with measuring a frequency-dependent natural vibration behavior of the object by dynamically-mechanically exciting the object in a defined frequency range (f), wherein the exciting of the object is carried out by generating a body vibration by applying a test signal, and detecting a body vibration generated in the object as a result of the exciting, in particular a first natural resonance.Furthermore, a frequency-dependent natural vibration behavior of the object is simulated by generating a virtual digital representation of the object, in particular a 3D model, and performing a finite element analysis based on the virtual representation with simulated dynamic excitation of the virtual representation in a virtual frequency range that at least overlaps with the defined frequency range to generate a virtual body vibration, and calculating the virtual body vibration generated in the object due to the simulated excitation, in particular a second natural resonance. Furthermore, an object state is derived based on a comparison (34b) of the measured and the simulated frequency-dependent natural vibration behavior.