Directed Energy Deposition Fixturing for Thermal Expansion Control
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Solution Overview
Problem
In additive manufacturing using the directed energy deposition method, the thermal expansion of the workpiece between holding portions can cause surface distortion, leading to inaccurate material powder supply and decreased processing accuracy.
Innovation Solution
The method involves holding the workpiece with first and second holding portions that are separated, performing additive manufacturing by supplying material powder and emitting a laser beam, and relatively moving the holding portions away from each other during the process to mitigate surface distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the workpiece is held by separated first and second holding portions during laser processing, then the workpiece can be stably supported, but thermal expansion causes surface distortion between the holding portions
Solution Approach 1:
The patent applies the dynamics principle by making the distance between the first and second holding portions variable rather than fixed. The holding portions are configured to be movable relative to each other along the workpiece axis, allowing the system to adapt to thermal expansion dynamically during laser processing. This resolves the contradiction by maintaining stable support through the holding portions while preventing surface distortion by adjusting their separation distance to match the workpiece's thermal expansion.
2Device complexity
If the holding portions are fixed at a constant distance, then the device structure is simple, but material powder cannot be supplied accurately onto the distorted surface
Solution Approach 1:
The patent implements dynamics by configuring the holding portions with movable capabilities along the workpiece axis. This allows the distance between holding portions to be adjusted dynamically during processing to compensate for thermal expansion, thereby maintaining surface accuracy and ensuring precise material powder supply without requiring overly complex fixed structures.
Solution Approach 2:
The patent applies parameter changes by varying the distance parameter between the first and second holding portions during the laser processing operation. This parameter adjustment compensates for thermal expansion effects, maintaining the workpiece surface geometry and ensuring accurate material powder deposition despite the dynamic processing conditions.
3Productivity
If laser beam is emitted to the workpiece, then additive manufacturing is performed, but the workpiece thermally expands causing surface distortion
Solution Approach 1:
The patent resolves the contradiction between productivity and precision by implementing dynamic adjustment of the holding portions' distance during laser beam emission. This allows continuous additive manufacturing to proceed while simultaneously compensating for thermal expansion, maintaining surface accuracy throughout the processing operation.
Solution Approach 2:
The patent applies preliminary anti-action by pre-configuring the holding portions to be movable and positioning them to accommodate expected thermal expansion before it causes significant surface distortion. This preventive measure allows the system to counteract thermal expansion effects proactively during laser processing, maintaining manufacturing precision while enabling continuous additive manufacturing.
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 ensures accurate supply of material powder onto the workpiece surface, maintaining high processing accuracy by suppressing surface distortion due to thermal expansion.
Implementation Method 1
when the laser beam is emitted to the workpiece, the workpiece thermally expands
Data Source
AI summary
A method for processing a workpiece includes holding a workpiece by a first holding portion and a second holding portion that are disposed to be separated from each other, performing additive manufacturing on the workpiece by supplying material powder and emitting a laser beam to the workpiece held by the first holding portion and the second holding portion, and relatively moving the first holding portion and the second holding portion in a direction away from each other during at least a portion of performing the additive manufacturing on the workpiece.