Weld Bead Layer Design for Faster Additive Metal Deposition
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Solution Overview
Problem
Existing methods for manufacturing additively-manufactured objects using weld beads are inefficient due to variability in weld bead length, requiring frequent heating and torch movement, which increases takt time and reduces building efficiency, and existing powder head systems are not optimal for all shapes, relying on intuitive skill for direction selection.
Innovation Solution
A method and apparatus for designing and manufacturing additively-manufactured objects by depositing weld bead layers, utilizing a program to determine the optimal direction for continuous bead formation based on the object's shape, reducing the need for frequent heating and torch movement, and controlling bead size and shape through advanced welding conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If weld bead deposition is performed manually based on worker experience and intuition, then bead formation direction can be selected, but the process requires great skill and increases operation complexity
Solution Approach 1:
The system performs automatic bead formation direction determination and torch movement control based on the input three-dimensional data of the workpiece. The control unit automatically calculates the optimal bead formation directions and controls the torch to move along these directions, eliminating the need for manual operator intervention and reducing dependency on worker skill and intuition.
2Productivity
If weld bead deposition follows conventional methods without optimized direction selection, then the process is simpler to operate, but the continuously formed length is short and takt time increases
Solution Approach 1:
The control unit determines the optimal bead formation directions in advance by analyzing the three-dimensional data of the workpiece before actual deposition begins. This preliminary calculation of deposition paths allows the torch to follow optimized trajectories that maximize continuous formation length, reducing the frequency of heating cycles and torch repositioning operations.
Solution Approach 2:
The system optimizes bead formation directions to maximize the continuously formed length of weld beads. By calculating and following optimal deposition paths, the torch can form beads continuously for longer distances without interruption, reducing the frequency of heating cycles and torch movements, thereby maintaining continuous useful action and improving building efficiency.
3Ease of operation
If powder head system is used for melting powder, then bead formation direction selection is not required, but thermal head must scan horizontal section two-dimensionally uniformly which increases scanning time
Solution Approach 1:
The system segments the workpiece into multiple layers in the vertical direction and determines optimal bead formation directions for each layer independently based on the three-dimensional data. This segmentation allows the torch to follow optimized one-dimensional paths within each layer rather than performing two-dimensional uniform scanning, reducing scanning time while maintaining deposition quality.
Solution Approach 2:
The system transitions from two-dimensional uniform scanning in the horizontal section to one-dimensional optimized bead formation paths. By determining specific bead formation directions within each layer and moving the torch along these predetermined directions, the system reduces the scanning dimensionality from 2D to 1D, significantly reducing scanning time while maintaining deposition quality.
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 enables the efficient construction of additively-manufactured objects with reduced takt time by optimizing weld bead direction and size, enhancing building efficiency and quality.
Implementation Method 1
a filler metal is melted and solidified by the arc to form a weld bead
Implementation Method 2
a filler metal is melted and solidified by the arc to form a weld bead
Implementation Method 3
A 3D printer for building using a metal material produces an additively-manufactured object by melting a metal powder or a metal wire by use of a heat source such as a laser
Implementation Method 4
melting a metal powder or a metal wire by use of a heat source such as a laser or an electron beam
Data Source
Figure 1
Figure 2
Figure 3(A)~3(C)
AI summary
This method for designing a laminate molded article involves using shape data of a laminate molded article to perform layer decomposition of the shape of the laminate molded article at each bead height per layer of weld bead layers, and perform layer decomposition to generate a plurality of virtual bead layers. Next, at an intermediate layer disposed at the lamination-direction center of the plurality of virtual bead layers, a direction in which the layer-decomposed laminate molded article continuously extends is set as a reference direction. The bead size of a weld bead formed in the plurality of virtual bead layers is then adjusted by a bead shape in a cross-section orthogonal to the reference direction.