Weld Bead Modeling for Accurate Additive Manufacturing Layers
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in accurately reproducing the shape of additively-manufactured objects due to factors like molten metal dripping and heat input unevenness, leading to complex calculation requirements and reduced reproducibility.
Innovation Solution
The method involves dividing three-dimensional shape data into trapezoidal bead models with overlapping portions and rotating vertices to adjust the shape, allowing for simple calculation and high reproducibility in creating deposition plans for weld beads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the shape of the bead model is finely adjusted based on formation conditions of the weld beads, then the manufacturing precision of the additively-manufactured object is improved, but the calculation processing becomes complicated and the productivity decreases
Solution Approach 1:
The invention changes the geometric parameters of the bead model from standard circular cross-section to elliptical cross-section, and further to trapezoidal cross-section with overlapping portions. By modifying these geometric parameters to match the actual shape of weld beads formed during additive manufacturing, the model accurately predicts the outer edge shape without requiring complex calculations. This parameter change resolves the contradiction by achieving high manufacturing precision through simple geometric model adjustments rather than complex computational processes.
2Manufacturing precision
If the bead model shape is adjusted to account for dripping and heat input effects, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The invention segments the bead model into a trapezoidal cross-section with distinct geometric features (bottom line, top line, side lines, overlapping portions) that correspond to different physical phenomena during welding. The overlapping portions specifically account for dripping effects, while the trapezoidal shape captures heat input distribution. This segmentation allows the complex physical processes to be represented by simple geometric elements, resolving the contradiction between manufacturing precision and device complexity.
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 production of additively-manufactured objects with shapes closer to the target design by simplifying the calculation process and improving reproducibility, even with complex deposition patterns.
Implementation Method 1
the weld beads being formed by melting and solidifying a filler material
Implementation Method 2
using a heat source such as an arc
Data Source
AI summary
An additive manufacturing method includes dividing a three-dimensional model shape into a plurality of layers, and dividing each divided layer into a plurality of bead models. A trapezoidal bead model has four vertices. The dividing into the plurality of bead models includes, in the same layer, the bead model for a previously formed weld bead and the bead model for a subsequently formed weld bead that is adjacent to the previously formed weld bead are arranged to have an overlapping portion, and among four vertices of the bead model for the subsequently formed weld bead, selecting as a selected vertex the vertex positioned at an end of the bottom line of the bead model, the end being away from the overlapping portion, and rotating the other three vertices about the selected vertex to change a shape of the trapezoidal bead model.