Additive Manufacturing Path Planning for Bead Sagging Control
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Solution Overview
Problem
Conventional additive manufacturing methods face challenges in preventing sagging of molten metal due to large displacement of beads between layers, leading to decreased accuracy in formed objects.
Innovation Solution
An additive manufacturing path generation apparatus that divides the object into layers with controlled formation heights, generating formation paths that restrict bead displacement and incorporate a correction unit to adjust paths for collective layer formation within specified height limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an object is divided into layers along contour lines, then the manufacturing process can be simplified, but the amount of displacement of a bead of an upper layer deposited on a bead of a lower layer becomes large, causing sagging of molten metal
Solution Approach 1:
The invention changes the layer division method from conventional contour line-based division to a method that divides layers in the vertical direction with controlled formation heights. This parameter change in the layering approach ensures that bead displacement between layers is limited, preventing sagging of molten metal while maintaining manufacturing simplicity
Solution Approach 2:
The invention introduces dynamic adjustment of formation paths through a correction unit that modifies paths based on calculated formation heights. This dynamic correction ensures that each layer's formation height remains within specified limits, preventing excessive bead displacement and sagging while adapting to the object's geometry
2Productivity
If the formation height of beads is increased to reduce the number of layers, then productivity improves, but sagging of molten metal occurs due to excessive displacement
Solution Approach 1:
The invention optimizes the formation height parameter by dividing it into controlled segments. Rather than using a single large formation height, the system calculates and enforces maximum formation height limits for each layer, balancing productivity with precision by preventing sagging through parameter control
Solution Approach 2:
The invention implements a feedback mechanism where the correction unit continuously adjusts formation paths based on calculated formation heights. This feedback ensures that formation heights remain within specified limits, preventing sagging while maintaining efficient layer formation for productivity
Data Source
AI summary
An additive manufacturing path generation apparatus includes: a formation path generation unit that divides an additive manufacturing object into layers that are units of formation of the additive manufacturing object such that a formation height of a bead that forms the layers does not exceed an upper limit and generates formation paths that are paths for formation of the divided layers from layer definition information and a formation path surface, the layer definition information defining division of the additive manufacturing object into the layers, the formation path surface being a surface restricting positions of the formation paths; and a formation path correction unit that corrects the formation paths to a formation path that causes a plurality of layers to be partially formed in a collective manner while maintaining the formation height within a range between the upper limit and a lower limit.