Overlapping optimization of hybrid deposited and micro-rolling additive manufacturing
ISSN: 1355-2546
Article publication date: 12 January 2022
Issue publication date: 23 May 2022
Abstract
Purpose
This paper aims to summarize the influence law of hybrid deposited and micro-rolling (HDMR) technology on the bead morphology and overlapping coefficient. A better bead topology positively supports the overlapping deposited in multi-beads between layers while actively assisting the subsequent layer's deposition in the wire and arc additive manufacturing (WAAM). Hybrid-deposited and micro-rolling (HDMR) additive manufacturing (AM) technology can smooth the weld bead for improved surface quality. However, the micro-rolling process will change the weld bead profile fitting curve to affect the overlapping coefficient.
Design/methodology/approach
Weld bead contours for WAAM and HDMR were extracted using line lasers. A comparison of bead profile curves was conducted to determine the influence law of micro-zone rolling on the welding bead contour and fitting curve. Aiming at the optimized overlapping coefficient of weld bead in HDMR AM, the optimal HDMR overlapping coefficient curve was proposed which varies with the reduction based on the best surface flatness. The mathematical model for overlapping in HDMR was checked by comparing the HDMR weld bead contours under different rolling reductions.
Findings
A fitting function of the bead forming by HDMR AM was proposed based on the law of conservation of mass. The change rule of the HDMR weld bead overlapping spacing with the degree of weld bead rolling reduction was generated using the flat-top transition calculation for this model. Considering the damming-up impact of the first bead, the overlapping coefficient was examined for its effect on layer surface flatness.
Originality/value
Using the predicted overlapping model, the optimal overlapping coefficients for different rolling reductions can be achieved without experiments. These conclusions can encourage the development of HDMR technology.
Keywords
Acknowledgements
This work was financially supported by Key Special Project of “Intelligent Robot” (Grant number 2019yfb11311100), National Natural Science Foundation of China (Grant number 52175320), Technology Innovation Special Project of Hubei province (Grant number 2017AAA003), Special Research Program of Civil Aircraft (Grant number MJ-2017-G-60) and Major Science and Technology Projects (Grant number 2019ZX04001009).
Citation
Zhao, X., Wang, Y., Zhang, H., Li, R., Chen, X. and Fu, Y. (2022), "Overlapping optimization of hybrid deposited and micro-rolling additive manufacturing", Rapid Prototyping Journal, Vol. 28 No. 6, pp. 1086-1096. https://doi.org/10.1108/RPJ-03-2021-0061
Publisher
:Emerald Publishing Limited
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