Manufacture of complex thin-walled metallic objects using weld-deposition based additive manufacturing

Panchagnula, Jayaprakash Sharma; Simhambhatla, Suryakumar

doi:10.1016/j.rcim.2017.06.003

Cited by 113 publications

(24 citation statements)

References 17 publications

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“…This technology enables the users to quickly produce complex thin-walled structures such as meta-materials, auxetics, etc. (Similar processes also exist for this purpose [3,4]). The additive manufacturing field has been intensively studied for a decade (see [5,6] for reviews of the literature).…”

Section: Introductionmentioning

confidence: 79%

Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing

Weisz-Patrault

2020

Additive Manufacturing

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In this contribution, a simplified macroscopic and semi-analytical thermal analysis of directed energy deposition (DED) is presented to obtain computationally efficient simulations of the entire process. Solidification and solid-state phase transitions are taken into account. The model is derived for laser metal powder directed energy deposition, although it can be simply adapted for other focused thermal energy (e.g., electron beam, or plasma arc). The gas flow used for carrying the powder significantly influences cooling conditions, which is included in the model. The proposed simulation strategy applies to multilayer composites with a wide range of shapes in the horizontal plane and arbitrary laser scanning strategies (continuous way, back and forth, etc.). The proposed work provides a simple tool to study the influence of most process parameters, design in-situ experiments and in turn develop optimization loops to reach material requirements and specific microstructures. In-situ pyrometer measurements have been compared to the model, and good agreement has been observed with 2.6% error in average. The model is used to demonstrate the effect of various process parameters for a simple cylindrical geometry and a more complex auxetic cell.

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Section: Introductionmentioning

confidence: 79%

Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing

Weisz-Patrault

2020

Additive Manufacturing

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“…An additional complexity within reviewing the literature in this area is the variety of additive manufacturing technologies that are in use, each having their own particular processing requirements and associated challenges with regard to support structures. As a rapidly evolving manufacturing technology, new additive manufacturing technologies are being developed and will most likely continue to be developed in the future [11][12][13]. It is, therefore, perhaps timely that a review of the topic with regard to support structures is performed, so that newly developed additive manufacturing technologies can exploit the most apposite strategies for support structure optimization, making AM a more sustainable technology.…”

Section: Methodsmentioning

confidence: 99%

Support Structures for Additive Manufacturing: A Review

Jiang

Stringer

2018

JMMP

303

154

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Additive manufacturing (AM) has developed rapidly since its inception in the 1980s. AM is perceived as an environmentally friendly and sustainable technology and has already gained a lot of attention globally. The potential freedom of design offered by AM is, however, often limited when printing complex geometries due to an inability to support the stresses inherent within the manufacturing process. Additional support structures are often needed, which leads to material, time and energy waste. Research in support structures is, therefore, of great importance for the future and further improvement of additive manufacturing. This paper aims to review the varied research that has been performed in the area of support structures. Fifty-seven publications regarding support structure optimization are selected and categorized into six groups for discussion. A framework is established in which future research into support structures can be pursued and standardized. By providing a comprehensive review and discussion on support structures, AM can be further improved and developed in terms of support waste in the future, thus, making AM a more sustainable technology.

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“…Since the definition of the surface is based on a 2-D generating curve rotating about an axis, the first builddirection of a layer can be calculated tangent to this line in the plane containing it [40], in order to be tangent to the surface and normal to the path. The other builddirections are calculated by rotating the first one about the rotation axis ( Figure 2).…”

Section: Path Planning and Build-direction Calculationmentioning

confidence: 99%

Layer-by-layer generation of optimized joint trajectory for multi-axis robotized additive manufacturing of parts of revolution

Chalvin

Campocasso

Hugel

et al. 2020

Robotics and Computer-Integrated Manufacturing

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This work focuses on additive manufacturing by Directed Energy Deposition (DED) using a 6-axis robot. The objective is to generate an optimized trajectory in the joint space, taking into account axis redundancy for parts of revolution produced with a coaxial deposition system. To achieve this goal, a new layer-by-layer method coupled with a trajectory constrained optimization is presented. The optimization results are theoretically compared to a nonoptimized trajectory and a point-by-point optimized trajectory. The layer-by-layer generation of optimized trajectories is validated experimentally on a 6-axis robot using a PLA extrusion system. Experimental results show that the layerby-layer trajectory optimization strategy applied to parts of revolution provides better geometrical accuracy while improving the efficiency of the manufacturing device compared to non-optimized solutions.

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Manufacture of complex thin-walled metallic objects using weld-deposition based additive manufacturing

Cited by 113 publications

References 17 publications

Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing

Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing

Support Structures for Additive Manufacturing: A Review

Layer-by-layer generation of optimized joint trajectory for multi-axis robotized additive manufacturing of parts of revolution

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