Additive Manufacturing Thermal Mapping for Defect Localization
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Solution Overview
Problem
Current additive manufacturing techniques face challenges in calculating the temperature history of metal objects quickly, leading to lengthy calculations and increased likelihood of structure defects, which are difficult to identify and rectify.
Innovation Solution
An additive-manufactured object design supporting device that analyzes both macro- and micro-regions using product shape, material, and modeling conditions, extracts local temperature history from a database, maps structure distribution, and identifies defective structures by comparing against allowable conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature history calculation is performed for the entire modeled object using fine mesh, then the temperature history accuracy is improved, but the calculation time increases significantly
Solution Approach 1:
The modeled object is divided into multiple regions (first region and second region) with different mesh densities. The first region contains the molten pool and uses fine mesh for accurate temperature history calculation, while the second region uses coarse mesh to reduce calculation complexity. This segmentation allows the system to achieve accurate temperature history where needed without the prohibitive computational cost of fine mesh throughout the entire object.
2Ease of manufacture
If the same mesh density is used throughout the modeled object, then the mesh generation is simplified, but the temperature history accuracy in critical regions is reduced
Solution Approach 1:
Different mesh densities are applied to different regions based on their importance for temperature history calculation. The first region (containing the molten pool) uses fine mesh to capture local temperature variations accurately, while the second region uses coarse mesh. This local quality approach ensures high measurement precision in critical areas without the complexity of uniformly fine mesh throughout the entire object.
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 rapid calculation of temperature history for each part, allowing for timely identification and prevention of structure defects, reducing reworking and improving design efficiency by clearly indicating defect locations.
Implementation Method 1
a portion having the modeling shape is melted and bonded by a laser or an electron beam
Implementation Method 2
a portion having the modeling shape is melted and bonded
Implementation Method 3
calculating the temperature history by a finite element method
Data Source
AI summary
When the temperature history in a fine mesh is obtained for the entire modeled object, it takes a huge amount of time in calculation. In order to solve the problem, An additive-manufactured object design supporting device, comprising: an analysis unit configured to analyze a modeling process of a macro-region and a micro-region by using a product shape, a material condition, and a modeling condition of a modeled object as input; a temperature history extraction unit configured to extract, from a temperature analysis result of the macro-region, a local temperature history by referring to a database that stores a temperature history of the micro-region; a mapping unit configured to map a structure distribution obtained from a temperature history distribution of the modeled object to the modeled object; and an extraction unit configured to extract a defective structure that does not satisfy a structure condition by using an allowable structure condition as input.