3D Curved Blade Bead Orientation Using Projected Formation Lines
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Solution Overview
Problem
In additively manufacturing three-dimensionally curved blades, determining the appropriate direction for bead formation is challenging, leading to increased waste and reduced yield due to inefficient cutting processes.
Innovation Solution
A method and apparatus that utilize three-dimensional shape data to slice the object into layers, divide each layer into regions, determine connection lines, estimate the extension direction of protrusions, and form beads along projected lines to efficiently build additively manufactured objects with optimized bead formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the forming direction of beads is not appropriately set when forming three-dimensionally curved blades, then the additive manufacturing process can be completed, but the cutting waste increases and yield decreases
Solution Approach 1:
The blade surface is divided into multiple regions by applying a preset set shape (such as a rectangle) to each sliced layer. This segmentation allows the determination of bead formation directions for each region based on the connection lines between adjacent regions, rather than attempting to determine a single direction for the entire blade surface.
Solution Approach 2:
The invention performs preliminary determination of bead formation directions by extracting connection lines between adjacent regions and calculating extension directions before actual bead formation. This preliminary action optimizes the bead formation path in advance, reducing cutting waste during subsequent processing.
2Manufacturing precision
If a complex calculation method is used to determine bead formation direction, then accuracy may improve, but the determination process becomes more complex and time-consuming
Solution Approach 1:
The system uses the geometric relationships inherent in the sliced layer data and preset set shapes to automatically determine connection lines and extension directions. The determination process leverages the structure of the data itself rather than requiring external complex calculation methods.
Solution Approach 2:
The invention changes the approach from complex continuous optimization to a discrete method based on preset set shapes and connection lines between regions. By parameterizing the problem in terms of region boundaries and connection line slopes, the solution achieves accuracy without excessive 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 accurate and efficient determination of bead formation direction, enhancing the manufacturing process by reducing waste and improving yield in additively manufacturing complex shapes.
Implementation Method 1
an additively-manufactured object including a protrusion extending in one direction is built by beads formed by melting and solidifying a filler metal
Implementation Method 2
an additively-manufactured object including a protrusion extending in one direction is built by beads formed by melting and solidifying a filler metal
Data Source
AI summary
Using three-dimensional shape data, the shape of a blade, which is an additive manufacturing product, is divided into multiple layers according to the height of a bead. Each layer of the additive manufacturing product that has been divided into multiple layers is divided by fitting regions of a set shape. By determining connecting lines for connecting the divided regions to each other and computing the extension directions of protrusions, planned lines for bead formation along said extension directions are determined. The additive manufacturing product is shaped by forming beads along planned bead formation lines.