Application of Linear Mixed-Effects Model, Principal Component Analysis, and Clustering to Direct Energy Deposition Fabricated Parts Using FEM Simulation Data

Abstract

The purpose of this study is to investigate the effects of toolpath patterns, geometry types, and layering effects on the mechanical properties of parts manufactured by direct energy deposition (DED) additive manufacturing using data analysis and machine learning methods. A total of twelve case studies were conducted, involving four distinct geometries, each paired with three different toolpath patterns based on finite element method (FEM) simulations. These simulations focused on residual stresses, strains, and maximum principal stresses at various nodes. A comprehensive analysis was performed using a linear mixed-effects (LME) model, principal component analysis (PCA), and self-organizing map (SOM) clustering. The LME model quantified the contributions of geometry, toolpath, and layer number to mechanical properties, while PCA identified key variables with high variance. SOM clustering was used to classify the data, revealing patterns related to stress and strain distributions across different geometries and toolpaths. In conclusion, LME, PCA, and SOM offer valuable insights into the final mechanical properties of DED-fabricated parts.