Modeling of bead section profile and overlapping beads with experimental validation for robotic GMAW-based rapid manufacturing

Xiong, Jun; Zhang, Guangjun; Gao, Hongming; Wu, Lin

doi:10.1016/j.rcim.2012.09.011

Cited by 173 publications

(88 citation statements)

References 18 publications

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“…3, the relative errors of all three models are within ±4%. Compared with relative errors up to 15% in previous literature [22,24], the model parameters identified in this study are much more accurate without considering the material loss during the welding process. This is mainly due to the use of curve fitting with detailed bead cross-sectional measurements instead of only employing the bead height and width in the model fitting.…”

Section: Curve Fitting Resultsmentioning

confidence: 71%

“…Cao et al [23] fitted the weld bead boundary with Gaussian, logistic, parabola and sine functions, and found that the sine function can fit the measured data with highest accuracy. Xiong et al [24] compared the measured weld beads under different welding parameters to three frequently-used profile models, namely circular arc, parabola, and cosine function. It was shown that the optimal model for the bead profile is largely dependent on the ratio of wire feed rate to welding speed.…”

Section: Single Bead Modellingmentioning

confidence: 99%

“…Previous research had used measured bead height and width instead of complete crosssectional profile for the model parameters identification. Nevertheless, the relative errors of bead cross-sectional area predicted by their models were as high as 15 -20% in certain circumstance [22,24]. Therefore, a further detailed measurement of the bead cross-sectional profile and the curve fitting based method are necessary for accurate modelling of bead geometry.…”

Section: Single Bead Modellingmentioning

confidence: 99%

See 2 more Smart Citations

A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM)

Ding

Pan

Cuiuri

et al. 2015

Robotics and Computer-Integrated Manufacturing

397

132

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Wire and arc additive manufacturing (WAAM) is a promising alternative to traditional subtractive manufacturing for fabricating large aerospace components that feature high buy-to-fly ratio. Since the WAAM process builds up a part with complex geometry through the deposition of weld beads on a layer-by-layer basis, it is important to model the geometry of a single weld bead as well as the multi-bead overlapping process in order to achieve high surface quality and dimensional accuracy of the fabricated parts. This study firstly builds models for a single weld bead through various curve fitting methods. The experimental results show that both parabola and cosine functions accurately represent the bead profile. The overlapping principle is then detailed to model the geometry of multiple beads overlapping together. The tangent overlapping model (TOM) is established and the concept of the critical centre distance for stable multi-bead overlapping processes is presented. The proposed TOM is shown to provide a much better approximation to the experimental measurements when compared with the traditional flat-top overlapping model (FOM). This is critical in process planning to achieve better geometry accuracy and material efficiency in additive manufacturing. Abstract: Wire and arc additive manufacturing (WAAM) is a promising alternative to traditional subtractive manufacturing for fabricating large aerospace components that feature high buy-to-fly ratio. Since the WAAM process builds up a part with complex geometry through the deposition of weld beads on a layer-by-layer basis, it is important to model the geometry of a single weld bead as well as the multi-bead overlapping process in order to achieve high surface quality and dimensional accuracy of the fabricated parts. This study firstly builds models for a single weld bead through various curve fitting methods. The experimental results show that both parabola and cosine functions accurately represent the bead profile. The overlapping principle is then detailed to model the geometry of multiple beads overlapping together. The Tangent Overlapping Model (TOM) is established and the concept of the critical centre distance for stable multi-bead overlapping processes is presented. The proposed TOM is shown to provide a much better approximation to the experimental measurements when compared with the traditional Flat-top Overlapping Model (FOM). This is critical in process planning to achieve better geometry accuracy and material efficiency in additive manufacturing.

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Section: Curve Fitting Resultsmentioning

confidence: 71%

Section: Single Bead Modellingmentioning

confidence: 99%

Section: Single Bead Modellingmentioning

confidence: 99%

See 1 more Smart Citation

A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM)

Ding

Pan

Cuiuri

et al. 2015

Robotics and Computer-Integrated Manufacturing

397

132

View full text Add to dashboard Cite

show abstract

“…Through depositing multi-bead and multi-layer structures, it was demonstrated that the traditional flat-top overlapping model [17] tends to under-estimate the optimal step-over distance, while TOM produces more stable deposition. Details of TOM could be found in the reference [18].…”

Section: E Verification Of Bead Modelmentioning

confidence: 99%

“…Hybrid approaches to "3D welding and milling" have been established to fabricate parts with a high quality surface finish [14,15]. The effects of bead modelling and process optimization in arc-welding-based AM were also investigated [16][17][18]. Recently, vision-sensing systems have been designed to on-line monitor and control the robotic arc welding process to deposit the desired geometry [19][20][21].…”

Section: Introductionmentioning

confidence: 99%