Weld Bead Trajectory Planning for Fatigue-Resistant Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing methods using weld beads often result in surface unevenness, leading to stress concentration and reduced fatigue strength, especially on internal surfaces where post-processing is difficult.
Innovation Solution
An additive manufacturing support device and method that determines a bead forming trajectory based on the maximum principal stress direction and load conditions, using stress analysis to optimize the weld bead deposition and improve fatigue strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If weld bead deposition is performed to build three-dimensional objects, then manufacturing capability and shape complexity are improved, but surface unevenness occurs leading to stress concentration and reduced fatigue strength
Solution Approach 1:
The patent performs stress analysis and determines optimal bead forming trajectories before actual additive manufacturing. By calculating maximum principal stress directions and planning trajectories in advance, the system prevents stress concentration from occurring in the first place, rather than addressing it after manufacturing
Solution Approach 2:
The patent changes the parameters of bead deposition by adjusting the bead forming trajectory based on stress analysis results. The trajectory determination unit modifies deposition parameters (direction, path, sequence) to align with maximum principal stress directions, thereby reducing stress concentration while maintaining manufacturing capability
2Manufacturing precision
If post-processing is applied to smooth outer surfaces, then surface quality is improved, but inner surface unevenness cannot be removed due to tool access limitations
Solution Approach 1:
The system performs trajectory optimization before manufacturing to prevent inner surface unevenness from forming. By calculating and determining optimal bead trajectories in advance that account for stress distribution, the need for post-processing is eliminated, especially for inaccessible inner surfaces
Solution Approach 2:
The additive manufacturing process itself is made to produce stress-concentration-free surfaces through intelligent trajectory control. The bead deposition process automatically adjusts its path to align with stress directions, making the manufacturing process self-correcting without requiring external post-processing operations
3Reliability
If bead forming trajectory is optimized based on stress analysis, then fatigue strength is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent replaces complex manual trajectory planning and post-processing operations with automated computational stress analysis and algorithmic trajectory determination. The system uses computer-based stress analysis and automated trajectory optimization to substitute for complex mechanical post-processing operations
Solution Approach 2:
The system implements a feedback loop where stress analysis results from the shape model inform trajectory determination, which then guides actual bead deposition. The trajectory is continuously optimized based on stress distribution feedback, creating a closed-loop system that automatically adjusts parameters
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
The solution effectively suppresses stress concentration and enhances fatigue strength by determining the optimal bead forming trajectory, ensuring the weld beads are deposited in a direction that minimizes stress concentration and meets or exceeds the design fatigue limit.
Implementation Method 1
a welding wire is melted and solidified by arc discharge to form a weld bead
Data Source
AI summary
An additive manufacturing support device includes a building condition acquisition unit configured to acquire information on a shape model of an object and a load condition applied to the object; a stress analysis unit configured to determine a maximum principal stress direction generated in each portion of the object, by stress analysis based on the acquired shape model and load condition; and a trajectory determination unit configured to determine a forming direction of a weld bead on the basis of the maximum principal stress direction and the load condition.