Additive Manufacturing Trajectory Planning with Unit-Block Bead Simulation
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Solution Overview
Problem
In additive manufacturing, creating a three-dimensional trajectory plan for weld bead formation is complex and time-consuming, making it difficult to evaluate and adjust the plan effectively, which can lead to reduced reproducibility of the manufacturing object.
Innovation Solution
A method that decomposes a three-dimensional shape model into linear models with polygonal cross-sections, sets a bead formation locus, generates polygonal columnar unit blocks, and simulates the weld bead formation for each unit block to create a trajectory plan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the trajectory plan is made three-dimensional to correctly evaluate the influence of bead formation path, then the evaluation accuracy is improved, but the plan complexity increases making it difficult to evaluate
Solution Approach 1:
The patent divides the three-dimensional manufacturing object into multiple linear models with polygonal cross-sections. Each linear model is further divided into unit blocks along the bead formation locus. This segmentation transforms the complex 3D trajectory evaluation into manageable 2D cross-sectional analyses, maintaining evaluation accuracy while reducing plan complexity.
2Manufacturing precision
If the bead model shape is finely adjusted based on formation conditions to improve manufacturing precision, then the manufacturing precision is improved, but the calculation processing becomes complicated and time-consuming
Solution Approach 1:
The patent performs preliminary decomposition of the 3D shape model into linear models with standardized polygonal cross-sections before trajectory planning. Unit blocks are pre-defined with standard shapes along the bead formation locus. This preliminary structuring enables subsequent trajectory evaluation and manufacturing without requiring complex real-time calculations, thus improving both precision and productivity.
3Device complexity
If the three-dimensional shape model is decomposed into linear models with polygonal cross-sections and unit blocks are generated, then the calculation complexity is reduced, but the model approximation error may increase
Solution Approach 1:
The patent applies different levels of geometric approximation to different parts of the model. The overall 3D shape is decomposed into linear models that preserve critical geometric features. Each linear model is divided into unit blocks with polygonal cross-sections that locally approximate the original geometry. This localized approximation strategy reduces calculation complexity while maintaining manufacturing precision by preserving essential shape characteristics in each local region.
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 allows for the correct evaluation of the trajectory plan's suitability without requiring complex calculations, enabling the creation of a plan with high reproducibility of the manufacturing object.
Implementation Method 1
a method of laminating weld beads in a desired shape, the weld beads being formed by melting and solidifying a filler metal (welding wire) using a heat source such as an arc
Data Source
AI summary
A trajectory plan creation assistance method for assisting creation of a trajectory plan acquires shape data of the manufacturing object, decomposes a three-dimensional shape model based on the shape data into a plurality of linear models each having a polygonal vertical cross section in a longitudinal direction, sets a bead formation locus for forming the weld bead along the linear model and the bead formation trajectory including a lamination order of the weld bead, generates a plurality of polygonal columnar unit blocks by dividing the linear model into unit lengths along the set bead formation locus, and creates the trajectory plan by simulating the formation of the weld bead for each of the unit blocks by simulation.