Additive Manufacturing Temperature Control With Optical Forging Feedback
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Solution Overview
Problem
The existing additive manufacturing technologies face challenges in achieving comprehensive performance and reducing internal defects due to coarse, directionally oriented crystals formed by the 'melting-solidification' method, and conventional temperature sensors struggle to effectively control the temperature at the forging position, affecting the surface quality and mechanical properties of the manufactured parts.
Innovation Solution
A temperature control system for additive manufacturing comprising a cladding device, a micro-forging device, a detecting device, a control module, and an adjusting module, which directs an energy beam to fuse material, detects internal effect parameters, calculates temperatures, and adjusts the energy source or micro-forging device to maintain a desired temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional temperature sensors are used to monitor temperature at the forging position, then the system is simple to implement, but the temperature control precision is insufficient due to the small gap between the forging device and forging position
Solution Approach 1:
The patent replaces conventional mechanical temperature sensors with an optical detection system. The detecting device uses optical fields to non-contactly measure temperature at the forging position, eliminating the need for physical contact and avoiding the limitation of small gaps between the forging device and workpiece. This substitution of mechanical measurement with optical measurement achieves precise temperature monitoring without increasing system complexity.
2Manufacturing precision
If the gap between the forging device and forging position is reduced to improve control, then the temperature control becomes more effective, but the device complexity increases due to the high complexity of the process and equipment
Solution Approach 1:
The patent introduces an optical field as an intermediary between the forging device and the forging position for temperature measurement. This intermediary enables temperature monitoring without requiring physical proximity or contact, thus maintaining effective temperature control while avoiding the complexity of reducing the physical gap between components.
Solution Approach 2:
The patent replaces mechanical temperature sensing with optical detection, allowing temperature measurement at the forging position without requiring the forging device to be in close physical contact with the workpiece. This substitution maintains temperature control effectiveness while simplifying the overall system architecture.
3Reliability
If real-time temperature monitoring is implemented to improve surface quality and mechanical properties, then the part quality improves, but the system complexity increases due to the need for detecting devices and control modules
Solution Approach 1:
The patent implements a feedback control system where the detecting device continuously monitors temperature at the forging position, and the control module adjusts process parameters based on this real-time information. This feedback mechanism ensures consistent surface quality and mechanical properties by maintaining optimal temperature conditions throughout the forging process.
Solution Approach 2:
The patent uses optical detection instead of mechanical temperature sensing to enable real-time monitoring. This approach provides the necessary feedback for quality control while avoiding the complexity associated with physical temperature sensors in the high-temperature, high-stress forging environment.
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 system enables precise real-time temperature control, improving the mechanical properties and surface quality of the manufactured parts by refining grains and reducing internal defects, allowing for the production of delicate and customized products with complex structures.
Implementation Method 1
using a high-energy beam such as a laser beam, an electron beam or an arc beam as a heat source to melt the synchronously fed metal material, such as metal powder, metal wire, and so on, which are stacked in layers
Implementation Method 2
A detecting device configured to detect a first internal effect parameter of the cladding layer at a forging position where it is forged by the micro-forging device
Implementation Method 3
thereafter rolling, shock processing and other treatments are used to refine the grains and improve internal quality
Implementation Method 4
adjust at least one of the first energy source and the micro-forging device to make the first calculated temperature at the forging position fall within a desired temperature range
Data Source
AI summary
The invention relates to a temperature control system for additive manufacturing and method for same. The temperature control system comprises: a cladding device configured to fuse a material and form a cladding layer, the cladding device comprising a first energy source; a micro-forging device coupled to the cladding device for forging the cladding layer; a detecting device; a control module; and an adjusting module coupled to at least one of the first energy source and the micro-forging device.