Wire-Beam Additive Manufacturing for Symmetric Bead Formation
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Solution Overview
Problem
Existing wire-type additive manufacturing methods face challenges in preventing off-centering of bead shapes due to angular differences between the wire feed direction and machining head travel direction, which complicates the process and reduces machining efficiency.
Innovation Solution
An additive manufacturing apparatus that controls a machining head with a wire nozzle, a beam source, and a gas nozzle to emit a beam and gas, respectively, while selecting machining conditions based on the angle between the wire feed direction and machining head travel direction to maintain a symmetrical bead shape without requiring rotation of the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the workpiece is rotated to maintain a constant angle between wire feed direction and machining head travel direction, then the bead shape symmetry is improved, but the device complexity increases due to the need for a rotation table and additional axes
Solution Approach 1:
Instead of rotating the workpiece to maintain constant angular relationship, the invention inverts the approach by keeping the workpiece stationary and rotating the machining head assembly. This achieves the same effect of maintaining optimal angle between wire feed and travel direction while avoiding the complexity of workpiece rotation mechanisms
Solution Approach 2:
The machining head is designed to perform multiple functions: it can rotate to adjust the angular relationship, feed the wire material, and move along the machining path. This multi-functionality eliminates the need for separate rotation tables and reduces overall device complexity while maintaining bead shape symmetry
2Manufacturing precision
If the workpiece is rotated to maintain constant angle between wire feed direction and machining head travel direction, then the bead shape symmetry is improved, but the machining region is reduced due to the need for a rotation table
Solution Approach 1:
The invention inverts the rotation approach by rotating the machining head instead of the workpiece. This eliminates the need for a rotation table that would occupy machining space, thereby preserving the full machining region area while still achieving constant angular relationship for symmetric bead formation
3Manufacturing precision
If the machining head is tilted to compensate for angular differences, then the bead shape symmetry is improved, but the device complexity increases due to additional adjustment mechanisms
Solution Approach 1:
The invention employs dynamic rotation of the machining head assembly to actively maintain the optimal angular relationship between wire feed direction and travel direction throughout the machining process. This dynamic adjustment is more efficient than static tilting mechanisms, achieving bead symmetry while reducing overall device complexity through a unified rotational degree of freedom
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 prevents off-centering of bead shapes using simple control methods, maintaining consistent bead width and height, and avoids complications associated with rotating the machining head, such as wire twisting and interference.
Implementation Method 1
a beam source capable of emitting a beam to the wire-like material
Implementation Method 2
a gas nozzle placed such that the beam source is interposed between the gas nozzle and the wire nozzle, the gas nozzle directing a gas toward the machining region
Data Source
AI summary
An additive manufacturing apparatus performs additive machining by controlling a machining head that includes a wire nozzle to feed a wire to a machining region on a surface of a base material, a beam source capable of emitting a beam to an end of the wire, and a gas nozzle placed such that the beam source is interposed between the gas nozzle and the wire nozzle, the gas nozzle directing a gas toward the machining region, and the additive manufacturing apparatus includes a machining-condition selection unit to obtain an angle that is formed between a direction in which the wire is fed and a travel direction of the machining head, when viewed in a direction in which the beam is emitted, and to select a machining condition for the additive machining on the basis of the angle.