3D Curved Blade Bead Path Planning to Reduce Cutting Waste

Solution Overview

Problem

In additively-manufactured objects with three-dimensionally curved blades, inappropriate setting of bead formation direction leads to increased waste and reduced yield during cutting processing, necessitating a method to efficiently determine the bead formation direction.

Innovation Solution

A manufacturing apparatus and program that utilize a welding robot with a building controller to generate a bead map and program for determining the optimal bead formation direction, allowing for efficient deposition of beads by dividing the object's shape into regions and controlling bead size and position based on three-dimensional model data.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If bead formation direction is not appropriately set in additive manufacturing of three-dimensionally curved blades, then the manufacturing process becomes simpler, but the cutting waste increases and yield decreases

Engineering Contradiction:

Improvebead formation direction settingVSAvoidcutting waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent applies parameter changes by systematically varying the bead formation direction parameters based on the blade's geometric characteristics. The method calculates optimal bead formation directions by changing key parameters such as the angle between the bead formation direction and the blade extension direction, allowing the manufacturing process to adapt to different blade shapes and sizes, thereby minimizing cutting waste while maintaining ease of manufacture

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements preliminary action by pre-calculating the optimal bead formation direction before the actual additive manufacturing process begins. The method performs preliminary calculations using the blade's three-dimensional model data to determine the best bead formation direction that will minimize subsequent cutting waste, so that when manufacturing starts, the optimal path is already established

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If bead formation direction is not appropriately set in additive manufacturing of three-dimensionally curved blades, then the manufacturing process becomes simpler, but the production yield decreases

Engineering Contradiction:

Improvebead formation direction settingVSAvoidproduction yield

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent applies parameter changes by systematically varying the bead formation direction parameters based on the blade's geometric characteristics. The method calculates optimal bead formation directions by changing key parameters such as the angle between the bead formation direction and the blade extension direction, allowing the manufacturing process to adapt to different blade shapes and sizes, thereby minimizing cutting waste while maintaining ease of manufacture

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements preliminary action by pre-calculating the optimal bead formation direction before the actual additive manufacturing process begins. The method performs preliminary calculations using the blade's three-dimensional model data to determine the best bead formation direction that will minimize subsequent cutting waste, so that when manufacturing starts, the optimal path is already established

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

Enables appropriate and easy determination of bead formation direction, enhancing the efficiency of additively-manufactured object production by reducing waste and improving yield.

Implementation Method 1

a bead is formed by use of an arc and filler metal

Methodology Applied

Scientific EffectArc heating: Electric Arc

Implementation Method 2

the arc heats and melts the filler metal to form a bead

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

depositing the molten metal

Methodology Applied

Scientific EffectMetal deposition: Deposition (physical)

Data Source

PatentEP3795277B1Production method and production apparatus for additive manufacturing product, and program

Publication Date: 2024.01.31 KOBE STEEL LTD

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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.