Additive Manufacturing Bead Planning With Selective Slag Removal
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Solution Overview
Problem
The existing additive manufacturing methods using 3D printers for slab metal production face reduced productivity due to the cumulative time required for impurity removal processes, and it is challenging to determine the necessity of impurity removal based on the adhesion and thickness of impurities like slag, which can lead to quality deterioration if not properly managed.
Innovation Solution
An additive manufacturing method that includes a bead formation process, impurity identification, and thickness estimation, allowing selective impurity removal only when the estimated thickness exceeds a predetermined threshold, thereby optimizing the impurity removal process and improving productivity without compromising the quality of the manufactured object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If impurity removal process is performed repeatedly after each weld bead deposition, then quality of manufactured object is maintained, but productivity is reduced due to cumulative time for impurity removal operations
Solution Approach 1:
The invention changes the parameter of impurity removal frequency from 'after every deposition' to 'selectively based on cumulative thickness'. By monitoring the cumulative thickness of deposited weld beads and comparing it against a threshold value, the system determines whether impurity removal is necessary, thus adjusting the removal frequency parameter dynamically rather than using a fixed schedule
Solution Approach 2:
The invention replaces the mechanical judgment process (manual inspection and decision-making about when to remove impurities) with an automated measurement and calculation system. The system automatically measures weld bead dimensions, calculates cumulative impurity thickness, and triggers removal operations based on predetermined criteria, substituting human judgment with automated sensing and control
2Productivity
If impurity removal operation is omitted to improve productivity, then time for impurity removal is reduced, but quality deteriorates due to incorporation of impurity into metal layer
Solution Approach 1:
The invention implements a feedback mechanism where the system continuously measures the dimensions of deposited weld beads, calculates the cumulative thickness of potential impurities, and uses this information to determine whether impurity removal is necessary. This closed-loop feedback system ensures that removal operations are performed only when actually needed to maintain quality
Solution Approach 2:
The invention performs preliminary measurement and calculation of cumulative impurity thickness before deciding whether to execute the impurity removal operation. By assessing the impurity thickness in advance and comparing it against a threshold, the system prepares the necessary information to make an informed decision about whether removal is required, avoiding unnecessary operations
3Measurement precision
If impurity thickness is measured directly at welding site, then measurement precision is improved, but measurement becomes difficult due to variation in electrical resistivity and saturation of area value
Solution Approach 1:
The invention introduces an intermediary calculation process that uses easily measurable parameters (weld bead area and height) to infer the cumulative impurity thickness. Instead of directly measuring the difficult-to-access impurity thickness at the welding site, the system measures the weld bead dimensions and calculates the impurity thickness as an intermediate value, making the measurement process feasible
Solution Approach 2:
The invention creates a computational model (copy) of the impurity formation process that relates weld bead dimensions to impurity thickness. By measuring the weld bead geometry and using the established relationship, the system obtains an accurate estimate of impurity thickness without directly measuring the impurity itself, thus avoiding the measurement difficulties
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 method enables the omission of unnecessary impurity removal processes, enhancing productivity while maintaining the quality of the manufactured object by accurately identifying and managing impurity adhesion, thereby preventing defects and ensuring high-quality weld beads.
Implementation Method 1
A 3D printer that manufactures a slab metal material uses a heat source such as a laser, an electron beam, and an arc to melt a metal powder or a metal wire
Implementation Method 2
A 3D printer that manufactures a slab metal material uses a heat source such as a laser, an electron beam, and an arc to melt a metal powder or a metal wire
Implementation Method 3
A 3D printer that manufactures a slab metal material uses a heat source such as a laser, an electron beam, and an arc to melt a metal powder or a metal wire
Implementation Method 4
forming a bead layer in which the weld beads are arranged... by melting and solidifying a filler metal
Data Source
AI summary
An additive manufacturing method is provided for producing a manufactured object by depositing weld beads formed by melting and solidifying a filler metal, the method including repeating the following three steps in the following order: forming a bead layer in which the weld beads are arranged, identifying a region where an impurity is generated on a surface of the formed bead layer, and estimating a thickness of the impurity in the identified region. The method further includes selectively removing the impurity from the surface after the estimating based on the estimated thickness of the impurity.