DED Compression Rig for In-Process Forging of Cylindrical Builds
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current Directed Energy Deposition (DED) additive manufacturing systems face inefficiencies due to sequential operation of deposition and compression phases, leading to increased processing time, uneven microstructure formation, and inability to produce components with forging-like qualities.
Innovation Solution
A DED system that integrates a rotary build table and a compression rig allowing simultaneous deposition and compression phases, utilizing a robotic arm and compression head with rollers to apply compressive loads during material deposition, controlled by a system that ensures uniform temperature and strain application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sequential operation of deposition and compression phases is used, then equipment complexity is reduced, but processing time increases
Solution Approach 1:
The patent combines the deposition head and compression rig into a single integrated system that operates simultaneously. The deposition head deposits material while the compression rig applies compressive loads to previously deposited layers, merging two previously sequential operations into one concurrent process, thereby reducing total processing time without significantly increasing equipment complexity
Solution Approach 2:
The system uses a robotic arm with multiple degrees of freedom to dynamically position both the deposition head and compression rig. The robotic arm can independently control the position and movement of each component, allowing flexible coordination of deposition and compression operations across different spatial locations, enabling simultaneous operation while maintaining operational simplicity
2Device complexity
If sequential operation of deposition and compression phases is used, then system simplicity is maintained, but microstructure uniformity deteriorates
Solution Approach 1:
The system maintains continuous compression action on deposited material by having the compression rig follow the deposition head in real-time. As the deposition head moves to new locations, the compression rig continuously applies loads to previously deposited layers, ensuring uniform microstructure development throughout the entire build process rather than allowing temperature and strain variations that occur with sequential operation
Solution Approach 2:
The system incorporates sensors and control systems that monitor the deposition process and dynamically adjust the compression rig's position and loading parameters. This feedback mechanism ensures that compression is applied at the optimal time and location to achieve uniform microstructure, maintaining manufacturing precision while using a relatively simple integrated system
3Productivity
If simultaneous deposition and compression is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The robotic arm serves multiple functions by simultaneously controlling both the deposition head and compression rig. This multi-functional approach allows the system to perform deposition, compression, and repositioning operations with a single integrated mechanism, increasing productivity while limiting the growth of device complexity through functional consolidation
Solution Approach 2:
The system divides the build space into distinct zones: the deposition head operates on the current layer being built, while the compression rig operates on previously deposited layers. This spatial segmentation allows both operations to proceed simultaneously without interference, enabling productivity improvement while keeping the device structure manageable through clear functional separation
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
This approach reduces processing time, ensures consistent microstructure homogeneity, and enables the production of components with forge-like properties without significant additional time or cost, allowing for both warm and cold rolling processes.
Implementation Method 1
DED apparatuses use a focused energy source, such as a laser or electron beam, to melt the feedstock material
Implementation Method 2
DED apparatuses use a focused energy source, such as a laser or electron beam, to melt the feedstock material
Implementation Method 3
a compression rig positioned proximate to the deposition assembly and having a compression head operable to continuously apply a compressive load to deposited melted feedstock material during deposition of the melted feedstock material
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A directed energy deposition (DED) additive manufacturing system may be utilized for manufacturing a cylindrical component from a feedstock material. The DED additive manufacturing system may comprise a rotary build table, a deposition assembly for depositing melted feedstock to form the component upon rotation of the build table, and a compression rig positioned proximate the deposition assembly and operable to continuously apply a compressive load to deposited melted feedstock material during deposition of the melted feedstock material.