DED Toolpath Segmentation for Non-Coaxial Wire-Beam Accuracy
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Solution Overview
Problem
The existing additive manufacturing methods, such as the DED method, face accuracy issues when the relative angle between the machining head's advancement direction and the wire supply direction changes, leading to inconsistencies in the manufacturing process, particularly when projected onto a plane perpendicular to the laser beam's irradiation direction.
Innovation Solution
The method involves dividing the machining path into multiple paths to ensure the machining head moves along the central axis of the wire supply when projected onto a plane perpendicular to the laser beam's direction, maintaining a specific relative angle between the beam and wire axes, allowing for precise control of the machining head's movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a tool path is created by running the machining head in reverse direction to a cutting path without considering wire supply direction, then the manufacturing process is simple, but the manufacturing precision degrades when the relative angle between advancement direction and wire supply direction changes
Solution Approach 1:
The machining path is divided into multiple divided machining paths based on the relative angle between the advancement direction and wire supply direction. This segmentation allows each path segment to be processed with appropriate angle control, resolving the contradiction by maintaining precision through division while keeping the overall process manageable.
Solution Approach 2:
The machining head movement is dynamically controlled to maintain a constant relative angle between the advancement direction and wire supply direction. The system adjusts the machining head's motion in real-time to ensure the relative angle remains within a predetermined range, thereby maintaining manufacturing precision throughout the process.
2Adaptability or versatility
If the machining head moves along complex paths with changing relative angles, then versatile manufacturing is achieved, but inconsistencies in bead width and height occur
Solution Approach 1:
Different segments of the machining path are processed with different control strategies based on the local relative angle requirements. Each divided machining path is optimized for its specific angular characteristics, allowing complex shapes to be manufactured while maintaining consistent bead dimensions through localized quality control.
Solution Approach 2:
The system dynamically adjusts the machining head's advancement direction to maintain a constant relative angle with the wire supply direction throughout the manufacturing process. This dynamic control ensures that bead width and height remain consistent even when manufacturing complex three-dimensional shapes.
3Productivity
If the relative angle between machining head advancement direction and wire supply direction is not controlled, then the manufacturing process is fast and simple, but the shape accuracy of the manufactured object deteriorates
Solution Approach 1:
The machining head's movement is dynamically controlled to maintain a constant relative angle with the wire supply direction throughout the additive manufacturing process. This dynamic angle control ensures high shape accuracy while maintaining efficient manufacturing speed by avoiding unnecessary process interruptions.
Solution Approach 2:
The patent replaces manual or simple automated path planning with an intelligent control system that automatically calculates and adjusts the machining head's advancement direction. This substitution of mechanical control with intelligent algorithms enables real-time angle optimization without sacrificing manufacturing speed.
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 enhances the accuracy of manufacturing complex shapes by maintaining a consistent relative angle between the machining head and wire supply direction, reducing inconsistencies in bead width and height, and improving the overall shape accuracy of the manufactured object.
Implementation Method 1
a beam nozzle to irradiate the machining region with a beam that melts the build material supplied to the machining region
Data Source
AI summary
An additive manufacturing method uses an additive manufacturing device performing additive machining by controlling a machining head including a nozzle to supply columnar build material to a machining region on a target surface and a beam nozzle to irradiate the machining region with beam melting the build material, the nozzle and the beam nozzle being provided non-coaxially. When additive machining is performed in a state where the machining head is located with central axes of the beam and the build material being positioned on a single vertical plane, the machining path is divided into divided machining paths such that the machining head is moved in one direction along a direction of the build-material central axis when motion of the machining head is projected onto a plane perpendicular to an irradiation direction of the beam, and the machining head is moved along each divided machining path to perform additive machining.