Process planning based on cylindrical or conical surfaces for five-axis wire and arc additive manufacturing

Abstract

Purpose

The study aims to fabricate large metal components with overhangs built on cylindrical or conical surfaces with a high dimensional precision. It proposes methods to address the problems of generating tool-paths on cylindrical or conical surfaces simply and precisely, and planning the welding process on these developable surfaces.

Design/methodology/approach

The paper presents the algorithm of tool-paths planning on conical surfaces using a parametric slicing equation and a spatial mapping method and deduces the algorithm of five-axis transformation by addressing the rotating question of two sequential points. The welding process is investigated with a regression fitting model on a flat surface, and experimented on a conical surface, which can be flattened onto a flat surface.

Findings

The paper provides slicing and path-mapping expressions for cylindrical and conical surfaces and a curvature-speed-width (CSW) model for wire and arc additive manufacturing to improve the surface appearances. The path-planning method and CSW model can be applied in the five-axis fabrication of the prototype of an underwater thruster. The CSW model has a confidence coefficient of 98.02% and root mean squared error of 0.2777 mm. The reverse measuring of the finished blades shows the residual deformation: an average positive deformation of about 0.5546 mm on one side of the blades and an average negative deformation of about −0.4718 mm on the other side.

Research limitations/implications

Because of the chosen research approach, the research results may lack generalizability for the fabrication based on arbitrary surfaces.

Originality/value

This paper presented an integrated slicing, tool-path planning and welding process planning method for five-axis wire and arc additive manufacturing.

Citation

Dai, F., Zhang, H. and Li, R. (2020), "Process planning based on cylindrical or conical surfaces for five-axis wire and arc additive manufacturing", Rapid Prototyping Journal, Vol. 26 No. 8, pp. 1405-1420. https://doi.org/10.1108/RPJ-01-2020-0001