Inclined Arc Weld Bead Lamination for Large Metal Modeling
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Solution Overview
Problem
Existing metal laminating and modeling methods face challenges in forming large modeled objects without significantly increasing the size of the apparatuses, as the gate-shaped frame and welding torch configuration become cumbersome and inefficient for larger projects.
Innovation Solution
A metal laminating and modeling method that involves setting a table and welding torch at specific inclination angles to form weld beads, allowing for the sequential lamination of metal layers while maintaining a compact apparatus size, by alternating between first and second inclination angles to control the flow and placement of weld beads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a gate-shaped frame with a welding torch is used to form large modeled objects, then the modeling capability is improved, but the apparatus size becomes excessively large
Solution Approach 1:
The patent introduces inclination angle as a new dimension of control. By tilting the table at different angles during the welding process, the welding torch can reach and form weld beads on surfaces that would otherwise be inaccessible or require a much larger apparatus. This dimensional change (adding angular orientation) allows compact apparatus to produce large modeled objects.
Solution Approach 2:
The patent changes the parameter of table inclination angle during the welding process. By adjusting the table angle between different welding steps, the same compact welding torch can effectively work on different portions of a large modeled object, eliminating the need for a large gate-shaped frame structure.
2Ease of operation
If the table inclination angle is increased to form weld beads on inclined surfaces, then the accessibility to large modeled objects is improved, but the weld bead placement precision may deteriorate due to gravity-induced metal flow
Solution Approach 1:
The patent employs periodic action by alternating between different table inclination angles during the welding process. The table is tilted at a first angle to form some weld beads, then tilted at a second (different) angle to form subsequent weld beads. This periodic change in inclination angle allows the process to exploit gravity beneficially at different stages, controlling metal flow to achieve precise weld bead placement while maintaining accessibility to inclined surfaces.
Solution Approach 2:
The patent makes the table inclination angle dynamic rather than static. By continuously or periodically changing the table angle during welding, the system adapts to the specific requirements of different welding positions and stages, maintaining both accessibility and precision throughout the modeling process.
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 the formation of large modeled objects while keeping the apparatuses compact, improving the quality of the modeled object's surfaces by controlling the flow and placement of weld beads, thus preventing protrusions and recesses, and reducing the need for additional processing steps.
Implementation Method 1
forming a weld bead that becomes a part of the modeled object by arc welding with the welding torch
Data Source
AI summary
A metal laminating and modeling method includes a first inclination angle modeling step including a first inclination step of setting a table on which the metal layers are to be formed at a first table inclination angle and setting a welding torch at a first torch inclination angle and a first welding step of forming a weld bead that becomes a part of the modeled object by arc welding with the welding torch and a second inclination angle modeling step including a second inclination step of inclining the table at a second table inclination angle that is larger than the first table inclination angle and setting the welding torch at a second torch inclination angle and a second welding step of forming the weld bead.