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CAM-system-based intelligent process planning and control of directed energy deposition for easy fabrication of accurate shape (本文)

上田, 真広 慶應義塾大学

2020.09.21

概要

In this thesis, aiming at the successful creation of parts by using DED type AM system, the dedicated computer aided manufacturing (CAM) system entitles “CAMAM” (CAM software for DED-type AM system) has been proposed and its prototype has been developed. CAMAM focuses on autonomous DED process planning that consists of nozzle motion path generation and evaluation of operation variables, which are nozzle motion speed, laser power and powder mass flow rate, and workpiece orientation control. Also, the feasibility of CAMAM has been studied experimentally by applying CAMAM to generate the NC programs and performing deposition experiment of several parts.

In the first chapter of this thesis, background and purpose of this research are described by introducing the DED principle and significant issues that the current process planning methods have, and the necessity of dedicated CAM system is emphasized. The research motivation is based on lack of effective solutions for DED process planning and the objective that is the development of CAMAM is declared. Approach taken in this study to achieve research objective is showed.

In Chapter 2, DED process planning using proposed CAMAM is explained. For quick development and efficient deployment of CAMAM, it has been decided to add DED process planning capabilities to a commercial CAM software for traditional subtractive machining as an add-in module. Firstly, DED path generation methodology is proposed as reverse play of the virtual cutting tool path which machines the whole object to the zero volume. Taking advantage of the existing cutting tool path generation functions that the base CAM software has, this alternative methodology is realized. Also, a method of adaptive control of deposition volume by adjusting operation variables at each deposition point based on deposition volume calculated by virtual cutting simulation is proposed. Moreover, importance of workpiece orientation control that the surface to be deposited keeps being perpendicular relative to the laser nozzle which direction is fixed in the gravity direction is emphasized by illustrating the effect that shape of the laser irradiated area and powder distribution on the surface can be kept being uniform.

In Chapter 3, aiming at controlling synchronously three different kinds of operation variables and creating a workpiece with accurate shape, identification method of these response delay time has been proposed. According to the method, using the specific DED type AM system, the response delay time of operation variables has been identified. As the result, it has been found that the response delay time of laser application is 0.72 ±0.2 s and powder supply control has about 15 s response delay time while the identified response delay time of nozzle motion control is negligible compared to that of other two variables. After that, using identified response delay time, dead time compensation control has been adapted to absorb the response delay time of laser power and powder supply control. For laser power control, laser application commands should be indicated prior to reaching targeted positions. In case of powder supply control, a pseudo motion command should be inserted to absorb the response delay time before starting the subsequent actual deposition with the changed powder supply amount. Performing experimental studies, targeted deposition shapes have been achieved without unintended deposition and effectiveness of the proposed compensation control method has been confirmed.

In Chapter 4, in order to study influences of operation variables on deposition state, analytical model proposed by the path research has been applied to the DED operation performed in this study and the deposition regime is discussed referring to the velocity of powder particles coming from the nozzle, which is measured empirically. Moreover, the relationship between operation variables and deposition geometry has been evaluated by fabricating a series of single-track line under different operation conditions and performing regression analysis against measurement results of its geometry. From the viewpoint of the responsiveness, the nozzle feed rate is finally selected as the operation variable to adjust deposition volume at each deposition point, and adaptive control of deposition volume at each path point has become able to be carried out in DED operation that is planned by using CAMAM.

In Chapter 5, the feasibility of CAMAM has been studied by fabricating of one-, two-, and three- dimensional parts. As the result of one-dimensional part deposition, it has been confirmed that adaptive control of deposition volume by adjusting the nozzle feed rate can work effectively for achieving targeted geometry. Fabrication of two-dimensional part has indicated that any object should be divided with the same number of layer along deposition path direction and a variation of layer height occurred by the division should be adaptively controlled by adjustment of the nozzle feed rate in order to prevent the deposited shape from having undesirable stepping geometry. In addition, functionality of the proposed CAMAM has been proven by the geometrically accurate shape of the deposited three-dimensional part achieved with workpiece orientation control using simultaneous five axis motion and adaptive control of deposition volume. Furthermore, from the results of melt pool observation during deposition, it can be suggested that the melt pool which has sufficient temperature and size for deposition can be stably formed at the targeted position on the surface by controlling the workpiece orientation so as to get normal direction of the surface to be deposited be direction of the nozzle fixed in gravity direction throughout the operation, thus the deposition state itself become stable. In addition, deposition operations of multiple size three- dimensional parts have been planned by using proposed CAMAM and these deposition experiments have been carried out. As the result, it has been found that addition of a small cross angle tilt to outer passes and reduction of layer height to suit part size are important, and CAMAM has been modified such that these processing can be realized in operation planning as well.

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