Interlayer closed-loop control of forming geometries for wire and arc additive manufacturing based on fuzzy-logic inference

Interlayer closed-loop control of forming geometries for wire and arc additive manufacturing based on fuzzy-logic inference

Li, Yongzhe (Student TU Delft)
Li, Xinlei (Harbin Institute of Technology)
Zhang, Guangjun (Harbin Institute of Technology)
Horvath, I. (TU Delft Cyber-Physical Systems)
Han, Qinglin (Harbin Institute of Technology)

2021

The deposition process of wire and arc additive manufacturing (WAAM) is usually planned based on a bead geometry model (BGM), which represents the relationship between bead geometries (e.g. width, height) and required deposition parameters. However, the actual deposition situation may deviate from the one in which the BGM is built, such as varied heat dissipation conditions, resulting in morphological changes of deposited beads and geometrical errors in the formed parts. In this paper, a novel control mechanism for enhancing the fabrication accuracy of WAAM based on fuzzy-logic inference is proposed. It considers the geometrical errors measured on already deposited layers and deposition context to adjust deposition parameters of beads in the subsequent layer, forming an interlayer closed-loop control (ICLC) mechanism. This paper not only presents the theoretical fundamentals of the ICLC mechanism but also reports the technical details about utilizing this mechanism to control the forming height of multi-layer multi-bead (MLMB) components. A fuzzy-logic inference machine was applied as the core component for calculating speed change of bead deposition based on height error and previously applied change. In terms of validation, the effectiveness of the proposed control mechanism and the implemented controller was investigated through both simulative studies and real-life experiments. The fabricated cuboid blocks showed good accuracy in height with a maximum error of 0.20 mm. The experimental results implied that the proposed ICLC approach facilitates deposition continuity of WAAM, and thus enables process automation for robotic manufacturing.

Closed-loop control
Fuzzy-logic inference
Interlayer adjustment
Multi-layer multi-bead deposition
Wire and arc additive manufacturing

http://resolver.tudelft.nl/uuid:5a8af4ba-bbb9-448c-847f-58a91324ca98

https://doi.org/10.1016/j.jmapro.2020.04.009

2021-04-24

1526-6125

Journal of Manufacturing Processes, 63, 35-47

Institutional Repository

journal article

© 2021 Yongzhe Li, Xinlei Li, Guangjun Zhang, I. Horvath, Qinglin Han