Additive Manufacturing Temperature Control at the Micro-Forging Position
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Solution Overview
Problem
The challenge in additive manufacturing is the difficulty in controlling the temperature at the forging position due to the complexity of the process and equipment, leading to suboptimal mechanical properties and surface quality of the manufactured parts.
Innovation Solution
A temperature control system comprising a cladding device, micro-forging device, detecting device, and adjusting module, which uses energy sources and micro-forging to form and refine cladding layers, detects internal effect parameters, and adjusts energy sources and forging devices to maintain a desired temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional temperature sensors are used to monitor temperature at the forging position, then the monitoring capability is limited, but the equipment complexity increases and control effectiveness decreases due to the small gap between the forging device and forging position
Solution Approach 1:
The patent replaces conventional mechanical temperature sensors with a vision-based optical measurement system. The high-speed camera captures thermal radiation from the forging position, and temperature is calculated through image processing and thermal radiation analysis, eliminating the need for physical contact sensors in the narrow gap between the forging device and workpiece.
Solution Approach 2:
The patent introduces an intermediary optical system consisting of a high-speed camera and image processing algorithm. This intermediary captures thermal information indirectly through electromagnetic radiation, allowing temperature monitoring without direct physical contact, thus resolving the conflict between measurement precision and device complexity.
2Manufacturing precision
If the gap between the forging device and forging position is reduced to improve control precision, then measurement difficulty increases, but temperature control effectiveness decreases
Solution Approach 1:
The patent substitutes mechanical temperature sensing with optical detection using a high-speed camera. This allows temperature measurement at the forging position even when the gap is minimized, as the optical system can detect thermal radiation without physical contact, thereby maintaining both control precision and measurement capability.
Solution Approach 2:
The patent creates an optical copy or representation of the thermal state at the forging position through high-speed imaging. The camera captures thermal radiation patterns that represent the temperature distribution, allowing indirect observation and measurement without interfering with the narrow gap configuration.
3Adaptability or versatility
If real-time temperature monitoring is implemented to improve material scope and forging effect, then the system complexity increases, but the conventional sensor approach is ineffective due to the small gap
Solution Approach 1:
The patent replaces complex mechanical sensor arrangements with a streamlined optical measurement system. The high-speed camera and associated image processing provide real-time temperature data without requiring complex sensor positioning mechanisms, thus expanding material applicability while keeping system complexity manageable.
Solution Approach 2:
The patent enables the system to self-monitor temperature through optical detection of thermal radiation. The high-speed camera automatically captures temperature information without requiring external intervention or complex sensor management, allowing real-time monitoring that expands material scope while maintaining reasonable system complexity.
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 precise temperature control during additive manufacturing, improving the mechanical properties and surface quality of the manufactured parts by ensuring the temperature at the forging position is within a desired range.
Implementation Method 1
uses a high-energy beam such as a laser beam, an electron beam or an arc beam as a heat source to melt the synchronously fed metal material
Implementation Method 2
A detecting device configured to detect a first internal effect parameter of the cladding layer at a forging position
Implementation Method 3
A micro-forging device coupled to the cladding device for forging the cladding layer
Implementation Method 4
calculate a first calculated temperature at the forging position based on the first internal effect parameter. An adjusting module coupled to at least one of the first energy source and the micro-forging device and configured to receive the first calculated temperature and to adjust at least one of the first energy source and the micro-forging device to make the first calculated temperature at the forging position fall within a desired temperature range
Data Source
AI summary
A temperature control method for additive manufacturing includes directing an energy beam of a first energy source toward a material and fusing at least a portion of the material to form a cladding layer, forging the cladding layer with a micro-forging device, and detecting a first internal effect parameter of the cladding layer at a forging position where is forged by the micro-forging device. The first internal effect parameter includes at least one of a stress or a strain of the cladding layer. The method also includes calculating a first calculated temperature of the cladding layer at the forging position based on the first internal effect parameter and adjusting the at least one of the first energy source and the micro forging device if the first calculated temperature does not fall within a desired temperature range.