Additive Manufacturing Support Control for Thermal Expansion
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Solution Overview
Problem
Conventional additive manufacturing methods struggle with thermal expansion issues in complex-shaped workpieces, leading to prolonged calculation times for thermal expansion amounts.
Innovation Solution
An additive manufacturing apparatus with a control unit that monitors and controls the torque applied to a drive unit to maintain a predetermined target value, adjusting the position of a support unit to compensate for thermal expansion and contraction, thereby preventing distortion and residual stress in complex-shaped workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conventional method of calculating thermal expansion amount based on temperature detection is used, then the thermal expansion can be compensated, but the calculation time becomes excessively long for complex-shaped workpieces
Solution Approach 1:
The patent replaces the conventional thermal calculation method (based on temperature detection and thermal expansion simulation) with a mechanical measurement method. A displacement sensor directly measures the actual thermal expansion displacement of the workpiece, converting a complex thermal field calculation problem into a simple mechanical measurement problem, thereby eliminating lengthy calculations while maintaining measurement accuracy.
Solution Approach 2:
The workpiece itself serves as the measurement object by directly detecting its own thermal expansion displacement through the displacement sensor. The system utilizes the workpiece's actual physical response (thermal expansion) as the measurement signal, eliminating the need for separate simulation calculations and achieving real-time, accurate thermal expansion compensation.
2Manufacturing precision
If the first and second holding units are moved away from each other to compensate for thermal expansion, then surface distortion is suppressed, but the control complexity increases
Solution Approach 1:
The patent implements a closed-loop feedback control system where the displacement sensor continuously monitors the workpiece's thermal expansion displacement, and the control unit automatically adjusts the relative position of the first and second holding units based on this real-time feedback. This ensures accurate compensation for thermal expansion while maintaining systematic and manageable control complexity through automated feedback mechanisms.
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 high-precision additive manufacturing on complex-shaped workpieces by dynamically adjusting to thermal changes, ensuring accurate deposition and reducing distortion and residual stress without simulating thermal expansion.
Implementation Method 1
When the workpiece is irradiated with a laser beam, the workpiece thermally expands
Data Source
AI summary
Provided is a technology for addressing thermal expansion in a way that is different from conventional methods during additive manufacturing on a workpiece.An additive manufacturing apparatus includes a laser head configured to perform additive manufacturing on a workpiece, a first support unit configured to support one side of the workpiece in a direction along a predetermined axis and rotatably support the workpiece with respect to the predetermined axis, a second support unit configured to support the other side of the workpiece in the direction along the predetermined axis and rotatably support the workpiece with respect to the predetermined axis, a drive unit configured to move the second support unit along the direction along the predetermined axis, a first detection unit configured to detect a physical quantity correlated with torque applied to the drive unit, and a control unit. The control unit executes a process of controlling the drive unit during at least one of additive manufacturing on the workpiece and cooling of the workpiece such that the physical quantity detected by the first detection unit approaches a predetermined target value.