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• W2945097547 abstract "Additive Manufacturing is of great interest to various industries looking tocreate a part directly from the CAD model in a very short span. Amongst thelaser, electron beam and arc based processes available today for themanufacture of fully dense metal parts, GMAW based arc wire deposition isof particular interest here owing to its advantages in terms of high materialdeposition rate, high power efficiency, lower investment costs, simpler setupand work environment requirements. The major challenge of weld-depositionmethod (also shared by processes based on other power sources) is the lack ofsupport mechanism for realizing overhanging features. The aim of theproposed research is to investigate slicing and path planning techniquesrequired for realizing such complex shapes. The associated investigations intothe weld-deposition parameters and the thermal behavior of the part are alsocarried out.In the absence of a support mechanism, the complexity of the componentsfabricated would be limited to undercut free geometries that involve 3-axiskinematics. If the overhang is small, the features can be realized by exploitingthe inherent overhanging capability of the weld-bead in 3-axis. However, ifthe overhang is large, the conventional 3-axis with uniform parallel slicingwill not be applicable. In such geometries, it is possible to realize morecomplex shapes by adding extra degrees of freedom or by using higher orderkinematics to the workpiece and/or to the deposition head by suitablyaligning the overhanging feature in-line to the deposition direction. Thekinematics analysis and coordinate frame transformations required for thesame are presented in this thesis. The associated slicing and path planningrequired for higher axis kinematics have been divided into two categories viz.,single-bead Multi-layer components and multi-bead Multi-layer componentsand analyzed separately. viiiSingle-bead Multi-layer components (or thin-walled components) refer tocomponents with a single weld-deposition pass and no inner area filling. Inthe fabrication of such single-bead Multi-layer structures, while thedeposition of the first layer is done on a flatwork plate, subsequent layers aredeposited on the previous weld-beads which are curved. A geometrical modeldeveloped for predicting the weld-bead geometry for such bead-on-beaddeposition. This mathematical model will be useful in the appropriate slicingof the CAD model, thus improving the dimensional accuracy of the structure.Multi-bead Multi-layer components, as the name reflects, involve multipleweld-deposition passes for a given layer. In the current study, objects withsudden or abrupt overhangs have been taken up for analysis. Someillustrative shapes, using the orthogonal weld-deposition were fabricated usingthis concept. Automated feature recognition (protrusion or depression andslots) from a tessellated CAD model and its deposition using higher orderkinematics was also presented. An in-house MATLAB code was developed torealize the same.Owing to the sequential nature of the weld-deposition process, different partsof the component have different thermal histories. Maintaining consistentthermal conditions for every layer is hence important for ensuring uniformproperties across the layers. A heat transfer conditions based thermalmodelling was carried out to determine the dwell time required for thecomponent to reach the required temperature." @default.
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• W2945097547 date "2017-01-01" @default.
• W2945097547 modified "2023-09-23" @default.
• W2945097547 title "Additive manufacturing of complex metallic objects with overhanging features: slicing and path planning strategies" @default.
• W2945097547 hasPublicationYear "2017" @default.
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