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Process planning for adaptive contour parallel toolpath in additive manufacturing with variable bead width

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Abstract

Lightweight structures with slender features and thin walls can be fabricated by the additive manufacturing process. The fabrication process utilizes a contour parallel toolpath, where sets of parallel contours are offset from the boundaries of a geometric structure at predefined intervals to deposit the material layer by layer. Currently, these intervals are set to be constant, which limits its capability to produce near net-shape parts. In recent research, the feasibility to fabricate parts using contour parallel toolpaths with variable bead widths has been explored to increase the production speed, to improve the geometry accuracy, and to manufacture void-free parts. However, existing process planning methods are computationally inefficient and challenging to implement. To resolve these issues, this paper proposes a comprehensive process planning framework for adaptive contour parallel toolpath with variable bead widths. More specifically, this framework includes a toolpath planning algorithm using the level-set method and a process planning algorithm for generating the desired bead geometry using a Gaussian process regression model. To validate the proposed framework, a case study has been demonstrated in the fabrication of benchmark features with a wire and arc additive manufacturing process.

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Acknowledgments

The authors acknowledge support from the Digital Manufacturing and Design (DManD) research center at the Singapore University of Technology and Design supported by the Singapore National Research Foundation.

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Authors and Affiliations

  1. Digital Manufacturing and Design Centre, Singapore University of Technology and Design, 8 Somapah Road, Singapore, 487372, Singapore

    Yi Xiong, Sang-In Park, Shaohui Foong & Gim Song Soh

  2. Engineering Product Development, Singapore University of Technology and Design, 8 Somapah Road, Singapore, 487372, Singapore

    Yi Xiong, Suhasini Padmanathan, Audelia Gumarus Dharmawan, Shaohui Foong, David William Rosen & Gim Song Soh

  3. The G. W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, 813 Ferst Drive NW, Atlanta, GA, 30332, USA

    David William Rosen

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  1. Yi Xiong
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  2. Sang-In Park
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  3. Suhasini Padmanathan
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  4. Audelia Gumarus Dharmawan
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  5. Shaohui Foong
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Correspondence to Gim Song Soh.

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Xiong, Y., Park, SI., Padmanathan, S. et al. Process planning for adaptive contour parallel toolpath in additive manufacturing with variable bead width. Int J Adv Manuf Technol 105, 4159–4170 (2019). https://doi.org/10.1007/s00170-019-03954-1

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  • DOI: https://doi.org/10.1007/s00170-019-03954-1

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