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Fabrication Sequence Optimization for Minimizing Distortion in Multi-Axis Additive Manufacturing

Weiming WangFred van KeulenJun Wu
Dec 2022
摘要
Additive manufacturing of metal parts involves phase transformations and hightemperature gradients which lead to uneven thermal expansion and contraction,and, consequently, distortion of the fabricated components. The distortion hasa great influence on the structural performance and dimensional accuracy, e.g.,for assembly. It is therefore of critical importance to model, predict and,ultimately, reduce distortion. In this paper, we present a computationalframework for fabrication sequence optimization to minimize distortion inmulti-axis additive manufacturing (e.g., robotic wire arc additivemanufacturing), in which the fabrication sequence is not limited to planarlayers only. We encode the fabrication sequence by a continuous pseudo-timefield, and optimize it using gradient-based numerical optimization. Todemonstrate this framework, we adopt a computationally tractable yet reasonablyaccurate model to mimic the material shrinkage in metal additive manufacturingand thus to predict the distortion of the fabricated components. Numericalstudies show that optimized curved layers can reduce distortion by orders ofmagnitude as compared to their planar counterparts.
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