NC Layer Shape Control for Temperature-Driven Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing apparatuses face challenges in achieving high machining accuracy due to the longer solidification time of materials at higher workpiece storage temperatures, leading to shape loss under gravity, despite determined command values.
Innovation Solution
A numerical control device that analyzes machining programs to extract storage temperatures, calculates layering volumes based on solidification times, and adjusts layer shapes to compensate for temperature-induced variations, thereby reducing solidification time and maintaining shape accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the workpiece storage temperature is high, then the material has more time to be supplied and processed, but the solidification time increases causing shape loss under gravity
Solution Approach 1:
The numerical control device performs preliminary analysis of the machining program to predict storage temperature distribution before actual machining. This allows pre-calculation of solidification times and pre-adjustment of layering parameters, enabling the system to compensate for temperature effects before they cause shape loss.
Solution Approach 2:
The system dynamically changes layering parameters (layering volume, shape, and position) based on the calculated storage temperature and solidification time relationships. By adjusting these parameters in response to temperature conditions, the system maintains shape accuracy despite varying thermal environments.
2Duration of action of moving object
If the material solidification time is long, then the material can be properly layered, but the layered material loses shape under gravity
Solution Approach 1:
The system applies preliminary anti-action by calculating the expected shape loss due to gravity during the predicted solidification time, and then adjusting the layering shape in advance to compensate for this expected deformation. This pre-compensation prevents the final shape loss.
Solution Approach 2:
The numerical control device performs preliminary calculation of solidification time based on storage temperature before material layering begins. This allows the system to pre-determine the appropriate layering volume and shape adjustments needed to counteract gravity-induced deformation during the solidification process.
3Productivity
If the beam output is increased to melt material faster, then the machining speed increases, but the workpiece temperature rises extending solidification time
Solution Approach 1:
The system uses feedback from the analyzed storage temperature data to adjust beam output and layering parameters. By monitoring the thermal state and adjusting process parameters accordingly, the system maintains optimal solidification times while preserving high machining speeds.
Solution Approach 2:
The numerical control device dynamically adjusts machining parameters including beam output and layering rate based on real-time temperature analysis. This dynamic adaptation allows the system to maintain high productivity while preventing excessive temperature rise that would extend solidification time.
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 additive manufacturing apparatus to perform machining with high accuracy by reducing shape loss and optimizing layer formation based on real-time temperature data, ensuring precise control over the machining process.
Implementation Method 1
Irradiation of a material and a workpiece with beams melts part of the workpiece, and a molten pool having a molten material accumulated therein is formed on the workpiece
Implementation Method 2
The molten material supplied into the molten pool then solidifies, and a layer made of the solidified molten material is formed on the workpiece
Data Source
AI summary
An NC device, which is a numerical control device, includes: a program analyzing unit that analyzes a machining program to obtain a movement path along which to move a supply position of a material on a workpiece; a storage temperature extracting unit that extracts, from data on surface temperature of the workpiece, storage temperature in an area including the movement path on the workpiece; a layering volume calculating unit that calculates a volume of a layer forming an object on the basis of a relation between the storage temperature and a volume of the material that solidifies at the storage temperature in a given time; and a layering shape changing unit that changes a shape of the layer on the basis of the volume of the layer.