Excess Thickness Setting for Additive Manufacturing Shape Accuracy
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Solution Overview
Problem
In additive manufacturing, residual stress generated during thermal shrinkage leads to deformation and errors in the target shape of built objects, necessitating excessive cutting allowances that increase manufacturing costs and time.
Innovation Solution
A method and device that predict thermal shrinkage and release strain deformations to adjust the excess metal amount, allowing for accurate building and machining by modifying the building shape to account for thermal and elastic deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the excess metal amount is increased to prevent shape errors during machining, then the manufacturing precision is improved, but the manufacturing cost and manufacturing time are increased
Solution Approach 1:
The patent applies preliminary action by predicting thermal shrinkage and release strain before machining occurs. The system calculates deformation amounts using finite element analysis and pre-determines the optimal excess metal amount needed, allowing the building plan to be adjusted in advance to compensate for expected deformations, thereby reducing the excess metal required while maintaining precision.
Solution Approach 2:
The patent implements feedback by using predicted deformation amounts to iteratively adjust the building plan. The system calculates thermal shrinkage and release strain, compares the predicted final shape with the target shape, and modifies the excess metal amount accordingly, creating a closed-loop optimization process that minimizes both material waste and machining time.
2Manufacturing precision
If the excess metal amount is increased to account for release strain, then the manufacturing precision is improved, but the manufacturing cost is increased
Solution Approach 1:
The system performs preliminary calculation of release strain using finite element analysis before the machining process. By predicting the deformation amount that will occur when excess metal is removed, the system can precisely determine the minimum necessary excess metal amount, avoiding unnecessary material consumption while ensuring the final shape meets precision requirements.
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting the excess metal amount based on calculated deformation parameters. Instead of using a fixed large allowance, the system modifies the excess metal thickness according to the specific deformation characteristics predicted for each region of the built object, optimizing material usage while maintaining shape accuracy.
3Manufacturing precision
If the excess metal amount is increased to allow for rough processing and finish processing, then the manufacturing precision is improved, but the machining time is increased
Solution Approach 1:
The system performs preliminary prediction of both thermal shrinkage and release strain to determine the optimal excess metal amount before machining begins. This advance calculation allows for more efficient machining planning, reducing the total amount of material that needs to be removed and thereby decreasing machining time while still achieving the required surface quality through optimized rough and finish processing.
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 improves the accuracy of building and machining while reducing manufacturing costs and time by optimizing the excess metal amount, ensuring precise shape retention and efficient processing.
Implementation Method 1
a filler metal is melted and solidified by the arc to form a bead
Implementation Method 2
a residual stress is generated inside a built object due to thermal shrinkage
Implementation Method 3
a residual stress is generated inside a built object due to thermal shrinkage
Implementation Method 4
deformation occurs due to release of the residual stress
Data Source
AI summary
An excess metal amount setting method includes: a thermal shrinkage prediction step of predicting a thermal shrinkage amount in the deposited body after manufacturing; a thermal shrinkage modifying step of obtaining a thermal deformation modifying profile by expanding a target profile according to the thermal shrinkage amount; a release strain prediction step of predicting an elastic deformation amount due to release strain of the deposited body after machining; an elastic deformation modifying step of obtaining an elastic deformation modifying profile by deforming the thermal deformation modifying profile according to the elastic deformation amount in a direction opposite to a deformation direction due to the release strain; and an excess metal amount setting step of adjusting an outer edge shape of the deposited body so that an excess metal amount from the elastic deformation modifying profile to an outer edge of the deposited body falls within a predetermined reference range.