Automated Tool‐Path Generation for Rapid Manufacturing of Additive Manufacturing Directed Energy Deposition Geometries

Biegler, Max; Wang, Jiahan; Kaiser, Lukas; Rethmeier, Michael

doi:10.1002/srin.202000017

Cited by 12 publications

(10 citation statements)

References 16 publications

(17 reference statements)

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“…Existing methods all need reconstruct surface to STL which is an intermediate form of 3D models for the generation of tool path. With the development of advanced machining technology, the technology of generating tool path directly from point cloud has been gradually developed in recent years [22][23][24][25]. Based on these methods, the tool path for remanufacturing is generated directly from point clouds without model reconstruction.…”

Section: Inputmentioning

confidence: 99%

“…The repairing process is complicated and inefficient because the reconstruction process requires a large amount of computation recourse. With the development of advanced machining, the technology of constructing machining trajectories directly with measured data has been gradually developed in recent years [22][23][24][25][26]. The codes based on above researches were wrote by MATLAB to generate tool paths directly from the point cloud.…”

Section: Defects Detectionmentioning

confidence: 99%

“…The tool path of post process is generated based on the nominal point cloud. Based on cross section algorithm [25], points are adjusted and arranged. The tool path could be generated by sorting all points by layers and connecting them in turns.…”

Section: Defects Detectionmentioning

confidence: 99%

See 2 more Smart Citations

An Octree-Based Two-Step Method of Surface Defects Detection for Remanufacture

Wen

et al. 2022

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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Accurate and quick detection has a significant bearing on overall productivity of remanufacture. 3D scanning technologies have been widely applied in defects detection by comparing the damaged model with the nominal model. In this process, a huge amount of point cloud data is required to ensure detection accuracy whereas resulting in large storage space and long processing time of detection. This paper proposed an efficient two-step method based on octree to detect defects accurately and quickly for remanufacturing. In this method, the damaged point cloud and the nominal point cloud are first registered.Then a two-step detection approach is developed to extract the surface defects, coarse detection and detailed extraction, where the octree method is applied to create an effective topology of discrete points and perform the Boolean operation for defects extraction. In coarse detection, rough location and size information of the defects are acquired from the whole point cloud data. Based on coarse detected boundary box containing defects, the detailed extraction step is applied to extract corresponding defects shape accurately. The feasibility of proposed method was validated by using a case to detect defects of a damaged turbine blade and the detection results can be used to generate restoration tool path. The results show that the proposed method outperforms state-of-art defects detection methods, which can reduce time by 74.03% and reduce error by 36.86%, respectively.

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Section: Inputmentioning

confidence: 99%

Section: Defects Detectionmentioning

confidence: 99%

See 1 more Smart Citation

An Octree-Based Two-Step Method of Surface Defects Detection for Remanufacture

Wen

et al. 2022

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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show abstract

“…Issue 1: Although many software codes have been developed for subtractive manufacturing processes, DED still lacks reliable and commercial solutions (Flores et al, 2019). For the generation of filling paths for irregular contours such as fusiform contours, the most commonly used parallel lines and zigzag paths (which can be derived from parallel lines) can lead to several subpaths and the parallel contours create problems with sharp angles, leading to inner cavities and surface waviness (Biegler et al, 2020). To achieve a stable and robust deposition process and maintain uniform growth of the part, it is also important to properly define the process parameters for the tool paths, such as TS and material feed speed (Flores et al, 2019).…”

Section: Multiaxis Motionmentioning

confidence: 99%

Multiaxis wire and arc additive manufacturing for overhangs based on conical substrates

Dai

Zhang²,

et al. 2021

RPJ

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Purpose This paper aims to present a series of approaches for three-related issues in multiaxis in wire and arc additive manufacturing (WAAM) as follows: how to achieve a stable and robust deposition process and maintain uniform growth of the part; how to maintain consistent formation of a melt pool on the surface of the workpiece; and how to fabricate an overhanging structure without supports. Design/methodology/approach The principal component analysis-based path planning approach is proposed to compute the best scanning directions of slicing contours for the generation of filling paths, including zigzag paths and parallel skeleton paths. These printing paths have been experimented with in WAAM. To maintain consistent formation of a melt pool at overhanging regions, the authors introduce definitions for the overhanging point, overhanging distance and overhanging vector, with which the authors can compute and optimize the multiaxis motion. A novel fabricating strategy of depositing the overhanging segments as a support for the deposition of filling paths is presented. Findings The second principal component of a planar contour is a reasonable scanning direction to generate zigzag filling paths and parallel skeleton filling paths. The overhanging regions of a printing layer can be supported by pre-deposition of overhanging segments. Large overhangs can be successfully fabricated by the multiaxis WAAM process without supporting structures. Originality/value An intelligent approach of generating zigzag printing paths and parallel skeleton printing paths. Optimizations of depositing zigzag paths and parallel skeleton paths. Applications of overhanging point overhanging distance and overhanging vector for multiaxis motion planning. A novel fabricating strategy of depositing the overhanging segments as a support for the deposition of filling paths.

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“…and commercialized [5][6][7]. However, most of these toolpath strategies are for conventional polymer 3D printers where the material extrusion can be interrupted.…”

Section: Introductionmentioning

confidence: 99%

A Continuous Toolpath Strategy from Offset Contours for Robotic Additive Manufacturing

Nguyen

King²,

Vargas-Uscategui³

et al. 2022

Preprint

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Toolpath planning is an essential component of robotic additive manufacturing. An efficient toolpath strategy allows parts to be made that are geometrically accurate, free of defects, have good mechanical properties and low residual stress. Toolpaths for cold spray additive manufacturing have some technical constraints that need to be considered compared to their counterpart designed for conventional 3D printing machines. This study presents an automated toolpath planning method based on offset contours. The generated toolpath is globally continuous, layer-wise setting, making it suitable for robotic cold spray additive manufacturing. The toolpath algorithm was tested on a variety of geometries to demonstrate its robustness. One model was selected for printing using a commercial high pressure cold spray system. The experimental results show that our method is applicable to cold spray robotic additive manufacturing. The method is particularly good for web-rib structures.

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Automated Tool‐Path Generation for Rapid Manufacturing of Additive Manufacturing Directed Energy Deposition Geometries

Abstract: The implementation of the zigzag path-planning strategy is shown in Figure 2 and follows six steps: 1) 2D area generation

Cited by 12 publications

References 16 publications

An Octree-Based Two-Step Method of Surface Defects Detection for Remanufacture

An Octree-Based Two-Step Method of Surface Defects Detection for Remanufacture

Multiaxis wire and arc additive manufacturing for overhangs based on conical substrates

A Continuous Toolpath Strategy from Offset Contours for Robotic Additive Manufacturing

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