A Novel Method for Additive Manufacturing of Complex Shape Curved Parts by Using Variable Height Layers
 
More details
Hide details
1
GeM - UMR CNRS 6183, Centrale Nantes, France
 
2
Additive Manufacturing Group, Joint Laboratory of Marine Technology (JLMT) Centrale Nantes - Naval Group, France
 
3
Naval Group Research, Technocampus Océan, France
 
 
Submission date: 2021-03-30
 
 
Final revision date: 2021-06-09
 
 
Acceptance date: 2021-06-10
 
 
Online publication date: 2021-07-19
 
 
Publication date: 2021-09-30
 
 
Corresponding author
Matthieu Rauch   

GeM - UMR CNRS 6183, Centrale Nantes, 1 rue de la Noë, 44321, nantes, France
 
 
Journal of Machine Engineering 2021;21(3):80-91
 
KEYWORDS
TOPICS
ABSTRACT
The Wire Arc Additive Manufacturing process (WAAM) is designed for the manufacture of large metallic parts. It is gaining its space inside the naval, aeronautics and space industries. However, there are key challenges to be solved in order to increase the performance of the WAAM process. Parts with curved shapes are difficult to manufacture with regular parallel layers without support because of an excessive overhang in certain regions. This paper proposes a methodology that solves this issue, by using incrementally angled layers with variable bead height, which eliminates or decreases the overhang between layers. This solution uses an angled rotary positioner (or other method for moving the part in a controlled way) and controls key parameters like the travel speed, the deposition angle, the available bead height difference, etc. The efficiency of the developed proposal is shown with the manufacture of a large curved steel (316L) piece as a use-case.
 
REFERENCES (19)
1.
ALONSO U., VEIGA F., SUÁREZ A., ARTAZA T., 2020, Experimental Investigation of the Influence of Wire Arc Additive Manufacturing on the Machinability of Titanium Parts, Metals, 10, 24.
 
2.
TABERNERO I., PASKUAL A., ÁLVAREZ P., SUÁREZ A., 2018, Study on Arc Welding Processes for High Deposition Rate Additive Manufacturing, Procedia CIRP, 68, 358–362.
 
3.
GAO W., ZHANG Y., RAMANUJAN D., RAMANI K., CHEN Y., WILLIAMS CB., WANG CC., SHIN YC., ZHANG S., ZAVATTIERI PD., 2015, The Status, Challenges, and Future of Additive Manufacturing in Engineering, Computer-Aided Design, 69, 65–89.
 
4.
QUERARD V., 2019, Réalisation de Pièces Aéronautiques de Grandes Dimensions Par Fabrication Additive WAAM, Génie mécanique. École centrale de Nantes. https://tel.archives-ouvertes...., (in French).
 
5.
DING D., PAN Z., CUIUIR D., LI H., 2015, A Multi-Bead Overlapping Model for Robotic Wire and Arc Additive Manufacturing (WAAM), Robotics and Computer-Integrated Manufacturing, 31, 101–110.
 
6.
ISA M., LAZOGLU I., 2019, Five-Axis Additive Manufacturing of Freeform Models Through Buildup of Transition Layers, Journal of Manufacturing Systems, 50, 69–80.
 
7.
HASCOËT J.Y., QUERARD V., RAUCH M., 2017, Interests of 5 Axis Toolpaths Generation for Wire Arc Additive Manufacturing of Aluminum alloys, Journal of Machine Engineering, 17/3, 51–65.
 
8.
MULLER P., HASCOET, J.Y., MOGNOL P., 2014, Toolpaths for Additive Manufacturing of Functionally Graded Materials (FGM) parts, Rapid Prototyping Journal, 20/6, 511–522.
 
9.
OGINO Y., ASAI S., HIRATA Y., 2018, Numerical Simulation of WAAM Process by a GMAW Weld Pool Model, Welding in the World, 62, 393–401.
 
10.
DING J., COLEGROVE P., MEHNEN J., et al., 2014, A Computationally Efficient Finite Element Model of Wire and Arc Additive Manufacture, Int. J. Adv. Manuf. Technol., 70, 227–236.
 
11.
DINOVITZER M., CHEN X., LALIGERTE J., HUANG X., FREI H., 2019, Effect of Wire and Arc Additive Manufacturing (WAAM) Process Parameters on Bead Geometry and Microstructure, Additive Manufacturing, 26, 138–146.
 
12.
RAGIEZAD M., GHAFFARI M., VAHEDI A., et al., 2019, Microstructural Evolution and Mechanical Properties of a Low-Carbon Low-Alloy Steel Produced by Wire Arc Additive Manufacturing. Int. J. Adv. Manuf. Technol., 105, 2121–2134.
 
13.
LEI Y., ZENGXI P., DONGHONG D., FENGYANG H., VAN DUIN S., HUIJUN L., WEIHUA L., 2020, Investigation of Humping Phenomenon for the Multi-Directional Robotic Wire and Arc Additive Manufacturing, Robotics and Computer-Integrated Manufacturing, 63, 101916.
 
14.
LAM T.F., XIONG Y., DHARMAWAN A.G., et al., 2020, Adaptive Process Control Implementation of Wire Arc Additive Manufacturing for Thin-Walled Components with Overhang Features, Int. J. Adv. Manuf. Technol., 108, 1061–1071.
 
15.
YILI D., SHENGFU Y., YUNSHENG S., et al., 2018, Wire and Arc Additive Manufacture of High-Building Multi-Directional Pipe Joint, Int. J. Adv. Manuf. Technol., 96, 2389–2396.
 
16.
XIZHANG C., SU C., WANG Y., et al., 2018, Cold Metal Transfer (CMT) Based Wire and Arc Additive Manufacture (WAAM) System, J. Surf. Investig., 12, 1278–1284.
 
17.
McNEIL JL, HAMEL WR., PENNEY J., NYCZ A., NOAKES M., 2019, Framework for CAD to Part of Large Scale Additive Manufacturing of Metal (LSAMM) in Arbitrary Direction, Solid Freeform Fabrication Symposium, 1126–1135.
 
18.
SATISH KUMAR P., SUVARNA RAJU L., SIVA RAMA KRISHNA L., 2020, A Review on Wire Arc Additive Manufacturing (WAAM) Fabricated Components of Ti6AL4V and Steels, International Conference on Emerging Trends in Engineering (ICETE), 2, 587–600.
 
19.
KNEZOVIĆ N., TOPIĆ A., 2019, Wire and Arc Additive Manufacturing (WAAM) – A New Advance in Manufacturing, International Conference, New Technologies, Development and Applications, 42, 65–71.
 
eISSN:2391-8071
ISSN:1895-7595
Journals System - logo
Scroll to top