Slicing strategy and process of laser direct metal deposition (DMD) of the inclined thin-walled part under open-loop control

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Liaoyuan Chen ◽  
Tianbiao Yu ◽  
Ying Chen ◽  
Wanshan Wang
Keyword(s):  
Dimensional Accuracy ◽  
Deposition Process ◽  
Open Loop ◽  
Adaptive Slicing ◽  
Content Type ◽  
Loop Control ◽  
Slicing Method ◽  
Deposition Thickness ◽  
Thin Walled ◽  
Deposition Height

Purpose The purpose of this paper is to improve the dimensional accuracy of inclined thin-walled parts fabricated by laser direct metal deposition (DMD) under an open-loop control system. Design/methodology/approach In this study, a novel method of the adaptive slicing method and DMD process with feedback adjustment of deposition height has been developed to successively fabricate complex inclined thin-walled square tube elbow parts. The defocus amount was used as a variable to the matching between the deposition thickness and the adaptive slicing height. Findings The low relative error of dimensional accuracy between experimental and designed parts shows that the matching of the single-layer deposition thickness and the adaptive slicing height can be realized by optimizing the defocusing amount. The negative feedback of the thin-wall part height can be achieved when the defocus amount and the z-axis increment are less than deposition thickness. The improvement of dimensional accuracy of inclined thin-walled parts is also attributed to the optimized scanning strategy. Practical implications The slicing method and deposition process can provide technical guidance for other additive manufacturing (AM) systems to fabricate metal thin-walled parts with high dimensional accuracy because the feedback control of deposition height can be realized only by the optimized process. Originality/value This study provides a novel adaptive slice method and corresponding the deposition process, and expands the slicing method of AM metal parts.

On the manufacturability of Inconel 718 thin-walled honeycomb structures by laser powder bed fusion

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
José M. Zea Pérez ◽  
Jorge Corona-Castuera ◽  
Carlos Poblano-Salas ◽  
John Henao ◽  
Arturo Hernández Hernández
Keyword(s):  
Mechanical Properties ◽  
Inconel 718 ◽  
Dimensional Accuracy ◽  
Honeycomb Lattice ◽  
Lattice Structures ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Content Type ◽  
Powder Bed ◽  
Thin Walled

Purpose The purpose of this paper is to study the effects of printing strategies and processing parameters on wall thickness, microhardness and compression strength of Inconel 718 superalloy thin-walled honeycomb lattice structures manufactured by laser powder bed fusion (L-PBF). Design/methodology/approach Two printing contour strategies were applied for producing thin-walled honeycomb lattice structures in which the laser power, contour path, scanning speed and beam offset were systematically modified. The specimens were analyzed by optical microscopy for dimensional accuracy. Vickers hardness and quasi-static uniaxial compression tests were performed on the specimens with the least difference between the design wall thickness and the as built one to evaluate their mechanical properties and compare them with the counterparts obtained by using standard print strategies. Findings The contour printing strategies and process parameters have a significant influence on reducing the fabrication time of thin-walled honeycomb lattice structures (up to 50%) and can lead to improve the manufacturability and dimensional accuracy. Also, an increase in the young modulus up to 0.8 times and improvement in the energy absorption up to 48% with respect to those produced by following a standard strategy was observed. Originality/value This study showed that printing contour strategies can be used for faster fabrication of thin-walled lattice honeycomb structures with similar mechanical properties than those obtained by using a default printing strategy.

Follow-the-leader motion strategy for multi-section continuum robots based on differential evolution algorithm

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
GuoHua Gao ◽  
Pengyu Wang ◽  
Hao Wang
Keyword(s):  
Differential Evolution ◽  
Kinematic Model ◽  
Differential Evolution Algorithm ◽  
Open Loop ◽  
Continuum Robots ◽  
Content Type ◽  
Loop Control ◽  
Continuum Robot ◽  
Motion Strategy ◽  
The Continuum

Purpose The purpose of this paper is to present a follow-the-leader motion strategy for multi-section continuum robots, which aims to make the robot have the motion ability in a confined environment and avoid a collision. Design/methodology/approach First, the mechanical design of a multi-section continuum robot is introduced and the forward kinematic model is built. After that, the follow-the-leader motion strategy is proposed and the differential evolution (DE) algorithm for calculating optimal posture parameters is presented. Then simulations and experiments are carried out on a series of predefined paths to analyze the performance of the follow-the-leader motion. Findings The follow-the-leader motion can be well performed on the continuum robots this study proposes in this research. The experimental results show that the deviation from the path is less than 9.7% and the tip error is no more than 15.6%. Research limitations/implications Currently, the follow-the-leader motion is affected by the following factors such as gravity and continuum robot design. Furthermore, the position error is not compensated under open-loop control. In future work, this paper will improve the accuracy of the robot and introduce a closed-loop control strategy to improve the motion accuracy. Originality/value The main contribution of this paper is to present an algorithm to generate follow-the-leader motion of the continuum robot based on DE. This method is suitable for solving new arrangements in the process of following a nonlinear path. Then, it is expected to promote the engineering application of the continuum robot.

Development of a deposition framework for implementation of a region-based adaptive slicing strategy in arc-based metal additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nitish P. Gokhale ◽  
Prateek Kala
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Complex Geometry ◽  
Dimensional Accuracy ◽  
Successful Implementation ◽  
Mathematical Function ◽  
Adaptive Slicing ◽  
Content Type ◽  
Metal Additive Manufacturing ◽  
Metal Additive

Purpose This study aims to develop and demonstrate a deposition framework for the implementation of a region-based adaptive slicing strategy for the Tungsten Inert Gas (TIG) welding-based additive manufacturing system. The present study demonstrates a deposition framework for implementing a novel region-based adaptive slicing strategy termed as Fast Interior and Accurate Exterior with Constant Layer Height (FIAECLH). Design/methodology/approach The mentioned framework has been developed by performing experiments using the design of experiments and analyzing the experimental data. Analysis results have been used to obtain the mathematical function to integrate customization in the process. The paper, in the end, demonstrates the FIAECLH framework for implementing region-based adaptive slicing strategy on the hardware level. Findings The study showcase a new way of implementing the region-based adaptive slicing strategy to arc-based metal additive manufacturing. The study articulating a new strategy for its implementation in all types of wire and arc additive manufacturing processes. Originality/value Wire-arc-based technology has the potential to deliver cost-effective solutions for metal additive manufacturing. The research on arc welding-based processes is being carried out in different dimensions. To deposit parts with complex geometry and better dimensional accuracy implementation of a novel region-based adaptive slicing strategy for the arc-based additive manufacturing process is an essential task. The successful implementation of an adaptive slicing strategy would ease the fabrication of complex geometry in less time. This paper accomplishes this need of implementing a region-based adaptive slicing strategy as no experimental investigation has been reported for the TIG-based additive manufacturing process.

A review of slicing methods for directed energy deposition based additive manufacturing

2018 ◽  
Vol 24 (6) ◽  
pp. 1012-1025 ◽  
Author(s):  
Jing Xu ◽  
Xizhi Gu ◽  
Donghong Ding ◽  
Zengxi Pan ◽  
Ken Chen
Keyword(s):  
Additive Manufacturing ◽  
Surface Quality ◽  
Energy Deposition ◽  
Support Structures ◽  
Adaptive Slicing ◽  
Content Type ◽  
Powder Bed ◽  
Directed Energy Deposition ◽  
Slicing Method ◽  
Directed Energy

Purpose The purpose of this paper is to systematically review the published slicing methods for additive manufacturing (AM), especially the multi-direction and non-layerwise slicing methods, which are particularly suitable for the directed energy deposition (DED) process to improve the surface quality and eliminate the usage of support structures. Design/methodology/approach In this paper, the published slicing methods are clarified into three categories: the traditional slicing methods (e.g. the basic and adaptive slicing methods) performed in the powder bed fusion (PBF) system, the multi-direction slicing methods and non-layerwise slicing methods used in DED systems. The traditional slicing methods are reviewed only briefly because a review article already exists for them, and the latter two slicing methods are reviewed comprehensively with further discussion and outlook. Findings A few traditional slicing approaches were developed in the literature, including basic and adaptive slicing methods. These methods are efficient and robust when they are performed in the PBF system. However, they are retarded in the DED process because costly support structures are required to sustain overhanging parts and their surface quality and contour accuracy are not satisfactory. This limitation has led to the development of various multi-direction and non-layerwise slicing methods to improve the surface quality and enable the production of overhangs with minimum supports. Originality/value An original review of the AM slicing methods is provided in this paper. For the traditional slicing methods and the multi-direction and non-layerwise slicing method, the published slicing strategies are discussed and compared. Recommendations for future slicing work are also provided.

A novel adaptive slicing algorithm based on ameliorative area ratio and accurate cusp height for 3D printing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Yifei Hu ◽  
Xin Jiang ◽  
Guanying Huo ◽  
Cheng Su ◽  
Hexiong Li ◽  
...  
Keyword(s):  
3D Printing ◽  
Surface Quality ◽  
Three Dimensional ◽  
Geometric Error ◽  
Area Ratio ◽  
Adaptive Slicing ◽  
Content Type ◽  
Contour Matching ◽  
Slicing Method ◽  
Cusp Height

Purpose Adaptive slicing is a key step in three-dimensional (3D) printing as it is closely related to the building time and the surface quality. This study aims to develop a novel adaptive slicing method based on ameliorative area ratio and accurate cusp height for 3D printing using stereolithography (STL) models. Design/methodology/approach The proposed method consists of two stages. In the first stage, the STL model is sliced with constant layer thickness, where an improved algorithm for generating active triangular patches, the list is developed to preprocess the model faster. In the second stage, the model is first divided into several blocks according to the number of contours, then an axis-aligned bounding box-based contour matching algorithm and a polygons intersection algorithm are given to compare the geometric information between several successive layers, which will determine whether these layers can be merged to one. Findings Several benchmarks are applied to verify this new method. Developed method has also been compared with the uniform slicing method and two existing adaptive slicing methods to demonstrate its effectiveness in slicing. Originality/value Compared with other methods, the method leads to fewer layers whilst keeping the geometric error within a given threshold. It demonstrates that the proposed slicing method can reach a trade-off between the building time and the surface quality.

Volumetric adaptive slicing of manifold mesh for rapid prototyping based on relative volume error

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Qianyong Chen ◽  
Jinghua Xu ◽  
Shuyou Zhang
Keyword(s):  
Rapid Prototyping ◽  
Surface Quality ◽  
Relative Volume ◽  
Confocal Laser ◽  
Adaptive Slicing ◽  
Content Type ◽  
Layer Height ◽  
Part Surface ◽  
Slicing Method ◽  
Cusp Height

Purpose Compared with cusp height and area deviation ratio, volume error (VE) caused by the layer height could represent the stair-case effect more comprehensively. The proposed relative volume error (RVE)-based adaptive slicing method takes VE rather than cusp height as slicing criteria, which can improve part surface quality for functionalized additive manufacturing. Design/methodology/approach This paper proposes a volumetric adaptive slicing method of manifold mesh for rapid prototyping based on RVE. The pre-height sequences of manifold mesh are first preset to reduce the SE by dividing the whole layer sequence into several parts. A breadth-first search-based algorithm has been developed to generate a solid voxelization to get VE. A new parameter RVE is proposed to evaluate the VE caused by the sequence of the layer positions. The RVE slicing is conducted by iteratively adjusting the layer height sequences under different constraint conditions. Findings Three manifold models are used to verify the proposed method. Compared with uniform slicing with 0.2 mm layer height, cusp height-based method and area deviation-based method, the standard deviations of RVE of all three models are improved under the proposed method. The surface roughness measured by the confocal laser scanning microscope proves that the proposed RVE method can greatly improve part surface quality by minimizing RVE. Originality/value This paper proposes an RVE-based method to balance the surface quality and print time. RVE could be calculated by voxelized parts with required accuracy at a very fast speed by parallel.

Open-loop control of compensation for optical propagation through a turbulent shear flow

1998 ◽  
Author(s):  
C. Truman ◽  
Lenore McMackin ◽  
Robert Pierson ◽  
Kenneth Bishop ◽  
Ellen Chen
Keyword(s):  
Shear Flow ◽  
Open Loop ◽  
Turbulent Shear ◽  
Turbulent Shear Flow ◽  
Open Loop Control ◽  
Loop Control ◽  
Optical Propagation

scholarly journals Sensuator: A Hybrid Sensor–Actuator Approach to Soft Robotic Proprioception Using Recurrent Neural Networks

Actuators ◽  
2021 ◽  
Vol 10 (2) ◽  
pp. 30
Author(s):  
Pornthep Preechayasomboon ◽  
Eric Rombokas
Keyword(s):  
Neural Networks ◽  
Recurrent Neural Networks ◽  
Linear Models ◽  
Open Loop ◽  
Proof Of Concept ◽  
State Estimator ◽  
Loop Control ◽  
Practical Applications ◽  
Soft Actuator ◽  
The Cost

Soft robotic actuators are now being used in practical applications; however, they are often limited to open-loop control that relies on the inherent compliance of the actuator. Achieving human-like manipulation and grasping with soft robotic actuators requires at least some form of sensing, which often comes at the cost of complex fabrication and purposefully built sensor structures. In this paper, we utilize the actuating fluid itself as a sensing medium to achieve high-fidelity proprioception in a soft actuator. As our sensors are somewhat unstructured, their readings are difficult to interpret using linear models. We therefore present a proof of concept of a method for deriving the pose of the soft actuator using recurrent neural networks. We present the experimental setup and our learned state estimator to show that our method is viable for achieving proprioception and is also robust to common sensor failures.

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