Multi-objective optimization of parts construction direction by scaling-enumeration method in L-PBF process

Abstract

Purpose

Part building orientation (PBO) is an important factor affecting the quality of laser powder bed fusion (L-PBF), which can affect the surface quality and manufacturing cost. The purpose of this paper is to propose a PBO optimization method to optimize the surface roughness and molding time of parts at the same time on the premise of small calculation scale and arbitrary resolution.

Design/methodology/approach

Efficient and accurate evaluation is an important index of PBO optimization method. In this paper, a PBO optimization method based on scaling enumeration method is proposed, and the surface roughness and molding time of L-PBF parts are modeled as the objective evaluation function of PBO optimization process. To realize multi-objective optimization, an expert system is established, and the fuzzy multiple-attribute group decision-making theory is used to provide weights for each objective evaluation function.

Findings

Research shows that the scaling-enumeration method can optimize the surface roughness and molding time at the same time and get the best PBO. Compared with the traditional method, the surface roughness and molding time are reduced by 1.1% and 0.58%, respectively, and the operation scale of the scaling-enumeration method is reduced by 99% compared with the traditional method. PBO with arbitrary angular resolution can be achieved.

Originality/value

This paper presents a new method to optimize the forming direction of L-PBF parts. This method has small operation scale and accurate results, so it is meaningful for industrial application.

Citation

Zhao, X. and Wang, T. (2024), "Multi-objective optimization of parts construction direction by scaling-enumeration method in L-PBF process", Rapid Prototyping Journal, Vol. 30 No. 6, pp. 1216-1229. https://doi.org/10.1108/RPJ-03-2023-0104