Feature-based five-axis path planning method for robotic additive manufacturing

2018 ◽  
Vol 233 (5) ◽  
pp. 1412-1424 ◽  
Author(s):  
Gang Zhao ◽  
Guocai Ma ◽  
Wenlei Xiao ◽  
Yu Tian
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Planning Method ◽  
Manufacturing Strategy ◽  
Feature Extraction Method ◽  
Manufacturing Method ◽  
Feature Based ◽  
Five Axis ◽  
Subtractive Machining ◽  
Manufacturing Features

Additive manufacturing has been developed for decades and attracts significant research interests in recent years. Usually, the stereolithography tessellation language format is employed in additive manufacturing to represent the geometric data. However, people gradually realize the inevitable drawbacks of the stereolithography tessellation language file format, such as redundancy, inaccuracy, missing of feature definitions, and lack of integrity. In addition, it is almost impossible to apply the simple polygonal facet representation to the five-axis manufacturing strategy. Hence, there are quite few researches and applications on the five-axis additive manufacturing, in spite of its common applications in the subtractive machining. This article proposes a feature-based five-axis additive manufacturing methodology to enhance and extend the additive manufacturing method. The additive manufacturing features are defined and categorized into two5D_AM_feature and freeform_AM_feature. A feature extraction method is proposed that can automatically recognize the additive manufacturing features from the input model. Specially for the freeform_AM_feature, a five-axis path planning method is proposed and split into three stages: (1) offset the reference surface, (2) spatially slice the freeform layers, and (3) generate the toolpaths for each freeform layer. Real additive manufacturing five-axis toolpaths can be obtained using the proposed algorithm that performs as a secondary developed plug-in in the CATIA® environment. A robotic additive manufacturing system is constructed for the implementation of the five-axis additive manufacturing tasks, which are generated by the proposed algorithms and post-processed after simulation and off-line programming. Some examples are printed to validate the feasibility and efficiency of the proposed method.

Process planning based on cylindrical or conical surfaces for five-axis wire and arc additive manufacturing

2020 ◽  
Vol 26 (8) ◽  
pp. 1405-1420
Author(s):  
Fusheng Dai ◽  
Haiou Zhang ◽  
Runsheng Li
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Process Planning ◽  
Flat Surface ◽  
Welding Process ◽  
Planning Method ◽  
Content Type ◽  
Tool Paths ◽  
Conical Surfaces ◽  
Five Axis

Purpose The study aims to fabricate large metal components with overhangs built on cylindrical or conical surfaces with a high dimensional precision. It proposes methods to address the problems of generating tool-paths on cylindrical or conical surfaces simply and precisely, and planning the welding process on these developable surfaces. Design/methodology/approach The paper presents the algorithm of tool-paths planning on conical surfaces using a parametric slicing equation and a spatial mapping method and deduces the algorithm of five-axis transformation by addressing the rotating question of two sequential points. The welding process is investigated with a regression fitting model on a flat surface, and experimented on a conical surface, which can be flattened onto a flat surface. Findings The paper provides slicing and path-mapping expressions for cylindrical and conical surfaces and a curvature-speed-width (CSW) model for wire and arc additive manufacturing to improve the surface appearances. The path-planning method and CSW model can be applied in the five-axis fabrication of the prototype of an underwater thruster. The CSW model has a confidence coefficient of 98.02% and root mean squared error of 0.2777 mm. The reverse measuring of the finished blades shows the residual deformation: an average positive deformation of about 0.5546 mm on one side of the blades and an average negative deformation of about −0.4718 mm on the other side. Research limitations/implications Because of the chosen research approach, the research results may lack generalizability for the fabrication based on arbitrary surfaces. Originality/value This paper presented an integrated slicing, tool-path planning and welding process planning method for five-axis wire and arc additive manufacturing.

A Study of Design Fixation Related to Additive Manufacturing

2018 ◽  
Vol 140 (4) ◽  
Author(s):  
Esraa S. Abdelall ◽  
Matthew C. Frank ◽  
Richard T. Stone
Keyword(s):  
Additive Manufacturing ◽  
Design For Additive Manufacturing ◽  
Negative Effects ◽  
Design Constraints ◽  
Basic Product ◽  
Manufacturing Method ◽  
Design Fixation ◽  
Negative Effect ◽  
Short Run ◽  
Manufacturing Features

This study aims to understand the effect of additive manufacturing (AM) on design fixation. Whereas previous research illustrates the positive aspects of AM, the overarching hypothesis of this work is that it might also have negative effects with respect to conventional manufacturability. In this work, participants from two groups, a design for conventional manufacturing (DfCM) group, and a design for additive manufacturing (DfAM) group, were asked to design a basic product. Then, a second iteration of the design asked both groups to design for conventional processes, and to include subtractive and formative methods like machining and casting, respectively. Findings showed that the DfAM fixated on nonproducible manufacturing features and produced harder to conventionally manufacture designs, even when told specifically to DfCM. There was also evidence that the complex designs of the DfAM group limited their modeling success and seemed to encourage them to violate more design constraints. This study draws attention to the negative effect of AM knowledge on designers and provides motivation for treatment methods. This is important if AM is used in prototyping or short run production of parts that are slated for conventional manufacturing later. The issue of design fixation is not a problem if AM is the final manufacturing method—a more common practice nowadays. This work suggests that one should consider the possibility of fixation in design environments where AM precedes larger volume conventional manufacturing.

scholarly journals Five-Axis Freeform Surface Color Printing Technology Based on Offset Curve Path Planning Method

2020 ◽  
Vol 10 (5) ◽  
pp. 1716
Author(s):  
Hongyao Shen ◽  
Bing Liu ◽  
Senxin Liu ◽  
Jianzhong Fu
Keyword(s):  
Path Planning ◽  
Planning Method ◽  
Freeform Surface ◽  
Surface Color ◽  
Printing Technology ◽  
Curve Path ◽  
Offset Curves ◽  
Color Printing ◽  
Five Axis ◽  
Offset Curve

Great progress has been made in 2D color printing with inkjet technology, and mature related products have come out, but there still exists great developmental space in 3D color printing. Therefore, a new path planning method based on the offset curve for 3D inkjet technology is proposed in this paper. Offset curves are generated on a freeform surface with geodesic equidistance, and then points for color printing are generated along the offset curves. In this paper, the principle of color printing technology with a 5-axis platform and the offset curve path planning (OCPP) method are presented. In addition, comparisons between the OCPP and adaptive filling algorithm based on the section method (AFSM) have been implemented. The OCPP significantly increased the rate of the theoretical filling area from 0.89 to 0.99 on a freeform surface.

A path planning method for robotic Additive Manufacturing

2021 ◽  
Author(s):  
Kevin Castelli ◽  
Ahmed Magdy Ahmed Zaki ◽  
Anikethan Yenjalagere Balakrishnappa ◽  
Marco Carnevale ◽  
Hermes Giberti
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Planning Method

scholarly journals A model for Manufacturing Large Parts with WAAM Technology

2021 ◽  
Author(s):  
Hoang Thanh Vo ◽  
Christelle Grandvallet ◽  
Frédéric Vignat
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Bead Geometry ◽  
Manufacturing Strategy ◽  
Heat Management ◽  
Cold Metal Transfer ◽  
Manufacturing Method ◽  
Wire Feed Speed ◽  
Component Shape ◽  
Cold Metal

Wire Arc Additive Manufacturing (WAAM) is a metallic additive manufacturing process based on the fusion of metallic wire using an electric arc as a heat source. The challenge associated with WAAM is heat management and understanding bead geometry. The printing process involves high temperatures, which results in the build-up of residual stresses can often cause deformations in a component. All of the process variables, such as torch speed (TS), wire feed speed (WFS), idle time, combine to produce the geometry of the deposit bead that results in the desired component shape. So, determining a method for choosing a good combined parameter process is very important to obtain a high-quality part. This article presents a study on how to use the WAAM process to produce a complexity part of aluminium alloys. The step of the determination process parameter is concentrated to develop in this study. An experimental design is determined to study the influence between the process parameters, for example, WFS, TS, high layer, length of bead. Different samples are made using the Yaskawa robot, using the classic CMT (Cold Metal Transfer) as a manufacturing method, using zigzag filling as a manufacturing strategy with the same WFS and same idle times and different TS, different bead lengths. A new manufacturing method using the zigzag filling strategy is proposed by adding an important step in determining the process parameters. The results indicate that the length of the bead has a significant impact on another parameter of the process.

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