Weld Bead Layer Planning for Faster Metal Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for additively manufacturing objects with metal materials, such as those described in Patent Literature 1, face inefficiencies in building complex shapes due to the need for frequent direction changes of the heat source, leading to increased takt time and reduced building efficiency, as the selection of optimal bead formation direction relies heavily on operator skill and experience.
Innovation Solution
A method that involves slicing the object shape into virtual bead layers, setting a reference direction for continuous formation, and adjusting bead size based on the bead shape perpendicular to this direction, allowing for more efficient deposition of weld beads by optimizing the continuous formation length and reducing unnecessary movement of the heat source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the bead formation direction is selected based on operator experience and intuition, then the building efficiency can be improved, but the method requires a great deal of skill and is not easily automated
Solution Approach 1:
The patent creates a virtual model of the workpiece and uses computational algorithms to determine optimal bead formation directions, copying the function of expert operator judgment into an automated computer-based system. The program automatically calculates and determines the bead formation directions without requiring operator skill or experience.
Solution Approach 2:
The patent replaces the manual mechanical process of visually assessing and determining bead directions with an automated computational system. The computer program uses algorithms to analyze the virtual workpiece model and automatically determine optimal bead formation paths, substituting human cognitive processes with automated computation.
2Manufacturing precision
If the heat source is frequently moved to next bead formation position, then the bead can be formed in desired shape, but the takt time for laminating and building increases
Solution Approach 1:
The patent performs preliminary planning by creating a virtual model of the workpiece and pre-calculating the optimal bead formation directions before actual manufacturing begins. This advance preparation allows the system to determine the most efficient deposition paths that minimize heat source movements while ensuring accurate bead formation.
Solution Approach 2:
The patent dynamically adjusts bead formation parameters based on the virtual model analysis. The system determines optimal bead directions and deposition parameters that adapt to the specific geometry of the workpiece, allowing for continuous or near-continuous bead formation without frequent direction changes.
3Ease of operation
If the thermal head scans horizontal section two-dimensionally uniformly, then the shaping can be performed without selecting bead formation direction, but the scanning time becomes long for some shapes
Solution Approach 1:
The patent introduces dynamic adaptability by using computational algorithms to determine optimal bead formation directions based on the specific workpiece geometry. Instead of using a fixed uniform scanning pattern, the system dynamically adjusts the bead deposition paths to match the workpiece shape, improving both efficiency and adaptability.
Solution Approach 2:
The patent changes the scanning parameters from uniform two-dimensional scanning to variable path scanning optimized for each specific workpiece. The system modifies the bead formation directions, lengths, and sequences based on the virtual model analysis, allowing for faster shaping while maintaining operational simplicity through automated parameter optimization.
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 building of additively manufactured objects with reduced takt time and improved efficiency by optimizing the continuous formation length of weld beads, thereby enhancing the overall manufacturing process.
Implementation Method 1
a weld bead formed by melting and solidifying a filler metal
Implementation Method 2
a weld bead formed by melting and solidifying a filler metal
Implementation Method 3
In the case of using an arc, a filler metal is melted and solidified by the arc to form a weld bead
Data Source
AI summary
A method for designing an additively-manufactured object includes: a slicing step of slicing a shape of the additively-manufactured object into weld bead layers each having a height corresponding to one bead layer using data of the shape of the additively-manufactured object, thereby generating a plurality of virtual bead layers; a reference direction setting step of setting, as a reference direction, a direction in which the sliced layer of the additively-manufactured object is continuously provided and extended in an intermediate layer disposed at a deposition-direction center of the plurality of virtual bead layers; and a bead adjusting step of adjusting a bead size of the weld bead to be formed in the plurality of virtual bead layers depending on a bead shape in a section perpendicular to the reference direction.