Modelling and optimising process of micro-plasma arc freeform fabrication
The main factors limiting the development of wire-based additive manufacturing (w-AM) are deposition process instability and deposition deviation caused by side feed. In this paper, the device tuning accuracy is introduced into the wire-arc deposition model for the first time, a wire-arc stable depo...
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2023-04-01
|
| Series: | Materials & Design |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127523002691 |
| _version_ | 1797843906251980800 |
|---|---|
| author | Bo Hong Yuanyuan Qu Yuxiang Hong Menglong Li Yeming Zou |
| author_facet | Bo Hong Yuanyuan Qu Yuxiang Hong Menglong Li Yeming Zou |
| author_sort | Bo Hong |
| collection | DOAJ |
| description | The main factors limiting the development of wire-based additive manufacturing (w-AM) are deposition process instability and deposition deviation caused by side feed. In this paper, the device tuning accuracy is introduced into the wire-arc deposition model for the first time, a wire-arc stable deposition model in micro-plasma arc directional energy deposition (mPA-DED) was established, and the process of the wire from contacting the micro-plasma arc (mPA) column to conducting stable metal transfer was carefully analyzed. A sensitivity coefficient describing the link between wire size and device adjustment precision in mPA-DED is proposed. The link between the sensitivity coefficient and the maximum meltable wire feeding speed and the threshold value of the maximum stable deposition speed was quantitatively analyzed, and the model was verified by cross-comparison experiments among the design wire size, arc size, and wire-arc position deviation. A well-formed 40-layer curved metal sample with a material area utilization ratio of 90.54 % was steadily deposited by using the proposed model and the optimized deposition parameters. This study offers theoretical guidance for designing an online control system for the deposition process to improve the stability of the fabrication process and deposition accuracy in micro-plasma arc freeform fabrication. |
| first_indexed | 2024-04-09T17:13:33Z |
| format | Article |
| id | doaj.art-2de5f5f2c5514d84b3e997efebed8470 |
| institution | Directory Open Access Journal |
| issn | 0264-1275 |
| language | English |
| last_indexed | 2024-04-09T17:13:33Z |
| publishDate | 2023-04-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj.art-2de5f5f2c5514d84b3e997efebed84702023-04-20T04:35:24ZengElsevierMaterials & Design0264-12752023-04-01228111854Modelling and optimising process of micro-plasma arc freeform fabricationBo Hong0Yuanyuan Qu1Yuxiang Hong2Menglong Li3Yeming Zou4School of Mechanical Engineering, Xiangtan University, Xiangtan 411105, ChinaSchool of Mechanical Engineering, Xiangtan University, Xiangtan 411105, China; Corresponding author.Key Laboratory of Intelligent Manufacturing Quality Big Data Tracing and Analysis of Zhejiang Province, China Jiliang University, Hangzhou 310018, ChinaSchool of Mechanical Engineering, Xiangtan University, Xiangtan 411105, ChinaSchool of Mechanical Engineering, Xiangtan University, Xiangtan 411105, ChinaThe main factors limiting the development of wire-based additive manufacturing (w-AM) are deposition process instability and deposition deviation caused by side feed. In this paper, the device tuning accuracy is introduced into the wire-arc deposition model for the first time, a wire-arc stable deposition model in micro-plasma arc directional energy deposition (mPA-DED) was established, and the process of the wire from contacting the micro-plasma arc (mPA) column to conducting stable metal transfer was carefully analyzed. A sensitivity coefficient describing the link between wire size and device adjustment precision in mPA-DED is proposed. The link between the sensitivity coefficient and the maximum meltable wire feeding speed and the threshold value of the maximum stable deposition speed was quantitatively analyzed, and the model was verified by cross-comparison experiments among the design wire size, arc size, and wire-arc position deviation. A well-formed 40-layer curved metal sample with a material area utilization ratio of 90.54 % was steadily deposited by using the proposed model and the optimized deposition parameters. This study offers theoretical guidance for designing an online control system for the deposition process to improve the stability of the fabrication process and deposition accuracy in micro-plasma arc freeform fabrication.http://www.sciencedirect.com/science/article/pii/S0264127523002691Additive manufacturingMicro-plasmaDeposition modelManufacturing stabilityCurved-metal wall |
| spellingShingle | Bo Hong Yuanyuan Qu Yuxiang Hong Menglong Li Yeming Zou Modelling and optimising process of micro-plasma arc freeform fabrication Materials & Design Additive manufacturing Micro-plasma Deposition model Manufacturing stability Curved-metal wall |
| title | Modelling and optimising process of micro-plasma arc freeform fabrication |
| title_full | Modelling and optimising process of micro-plasma arc freeform fabrication |
| title_fullStr | Modelling and optimising process of micro-plasma arc freeform fabrication |
| title_full_unstemmed | Modelling and optimising process of micro-plasma arc freeform fabrication |
| title_short | Modelling and optimising process of micro-plasma arc freeform fabrication |
| title_sort | modelling and optimising process of micro plasma arc freeform fabrication |
| topic | Additive manufacturing Micro-plasma Deposition model Manufacturing stability Curved-metal wall |
| url | http://www.sciencedirect.com/science/article/pii/S0264127523002691 |
| work_keys_str_mv | AT bohong modellingandoptimisingprocessofmicroplasmaarcfreeformfabrication AT yuanyuanqu modellingandoptimisingprocessofmicroplasmaarcfreeformfabrication AT yuxianghong modellingandoptimisingprocessofmicroplasmaarcfreeformfabrication AT menglongli modellingandoptimisingprocessofmicroplasmaarcfreeformfabrication AT yemingzou modellingandoptimisingprocessofmicroplasmaarcfreeformfabrication |