Additive Manufacturing Path Correction for Accurate Melt Deposition

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Solution Overview

Problem

Additive manufacturing apparatuses face challenges in producing shaped articles with high shape accuracy due to deviations in the position of molten product deposition, which cannot be effectively corrected by existing technologies.

Innovation Solution

An additive manufacturing apparatus that includes a machining head emitting a beam, a feed unit for material supply, and a control unit determining a corrected machining path based on the moving direction of the machining head, allowing for precise movement and correction of the machining path to align with the intended design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the material is fed to the machining point during additive manufacturing, then the material can be deposited to form the shaped article, but the material interrupts part of the beam causing asymmetric energy distribution and melt pool center deviation

Engineering Contradiction:

Improveshape accuracyVSAvoidbeam interruption

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The machining path is corrected in advance based on the moving direction of the machining head before the actual machining process. This preliminary correction compensates for the beam interruption effect caused by material feeding, ensuring that the melt pool center aligns with the intended deposition position without requiring real-time adjustments during machining.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system applies a counteracting correction to the machining path that anticipates and offsets the harmful effect of beam interruption. By calculating the expected deviation caused by material feeding and applying an equal and opposite correction to the path, the system prevents the melt pool center deviation before it occurs.

Inventive Principle:

Principle #9Preliminary anti-action

2Productivity

If the machining head moves along the original machining path, then the beam can be emitted to melt the material, but the molten product deposition position deviates from the design shape

Engineering Contradiction:

Improvemachining speedVSAvoiddeposition position accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The machining path is pre-corrected based on the moving direction of the machining head before machining begins. This allows the system to maintain high machining speed along the corrected path while ensuring that the molten product deposits at the intended design positions, eliminating the need for slow real-time path adjustments.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the position where material is supplied is adjusted depending on the moving direction of the machining head, then the material feed can be optimized, but the additive manufacturing apparatus still cannot correct the deviation of molten product deposition position

Engineering Contradiction:

Improvematerial feed controlVSAvoiddeposition position accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system performs preliminary correction of the machining path based on the moving direction of the machining head. This correction is applied before machining begins and maintains high machining speed while ensuring accurate deposition. The correction amount is determined by the moving direction, allowing the system to adapt to different machining directions without sacrificing precision.

Inventive Principle:

Principle #10Preliminary action

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

The apparatus achieves high shape accuracy by correcting the machining path and aligning the molten product deposition with the intended design, reducing deviations and improving the overall precision of the shaped articles produced.

Implementation Method 1

an additive manufacturing apparatus locally melts a material by a heat source such as a laser beam, an electron beam, or an arc

Methodology Applied

Scientific EffectLaser beam melting: Laser

Implementation Method 2

Energy of the heat source is absorbed by the workpiece, which causes a melt pool to be formed at the machining point on the workpiece

Methodology Applied

Scientific EffectThermal energy absorption: Absorption (EM radiation)

Implementation Method 3

The additive manufacturing apparatus brings the melted material into contact with the melt pool to join the melt of the material to the workpiece

Methodology Applied

Scientific EffectMaterial deposition: Deposition (physical)

Data Source

PatentUS12011779B2Additive manufacturing apparatus, additive manufacturing system, additive manufacturing method, storage medium, and learning device

Publication Date: 2024.06.18 MITSUBISHI ELECTRIC CORP

AI summary

An additive manufacturing apparatus produces a shaped article by adding a material melted by emission of a beam, to a workpiece. The additive manufacturing apparatus includes a machining head that emits the beam to the workpiece, a feed unit that feeds the material to the workpiece, and a numerical control device, which is a control unit that determines a machining path along which the machining head is caused to move with respect to the workpiece, and outputs a command to move the machining head. The control unit outputs a command to move the machining head along the machining path obtained by correction performed based on a moving direction of the machining head with respect to the workpiece.