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A model of bead size based on the dynamic response of CMT-based wire and arc additive manufacturing process parameters

Xuewei Fang (State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, China and National Innovation Institute of Additive Manufacturing, Xi’an, China)
Chuanqi Ren (National Innovation Institute of Additive Manufacturing, Xi’an, China)
Lijuan Zhang (National Innovation Institute of Additive Manufacturing, Xi’an, China)
Changxing Wang (State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, China and National Innovation Institute of Additive Manufacturing, Xi’an, China)
Ke Huang (The State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, China)
Bingheng Lu (School of Mechanical Engineering, IAMT, Xi’an, China and National Innovation Institute of Additive Manufacturing, Xi’an, China)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 17 May 2021

Issue publication date: 4 June 2021

229

Abstract

Purpose

This paper aims at fabricating large metallic components with high deposition rates, low equipment costs through wire and wire and arc additive manufacturing (WAAM) method, in order to achieve the morphology and mechanical properties of manufacturing process, a bead morphology prediction model with high precision for ideal deposition of every pass was established.

Design/methodology/approach

The dynamic response of the process parameters on the bead width and bead height of cold metal transfer (CMT)-based AM was analyzed. A laser profile scanner was used to continuously capture the morphology variation. A prediction model of the deposition bead morphology was established using response surface optimization. Moreover, the validity of the model was examined using 15 groups of quadratic regression analyzes.

Findings

The relative errors of the predicted bead width and height were all less than 5% compared with the experimental measurements. The model was then preliminarily used with necessary modifications, such as further considering the interlayer process parameters, to guide the fabrication of complex three-dimensional components.

Originality/value

The morphology prediction of WAAMed bead is a critical issue. Most research has focused on the formability and defects in CMT-based WAAM and little research on the effect of process parameters on the morphology of the deposited layer in CMT-based WAAM has been conducted. To test the sensitivities of the processing parameters to bead size, the dynamic response of key parameters was investigated. A regression model was established to guide the process parameter optimization for subsequent multi-layer or component deposition.

Keywords

Acknowledgements

This work was supported by The National Key Research and Development Program of China [grant number 2018YFB1106302] and China Postdoctoral Science Foundation [Grant number 2019M663682].

Citation

Fang, X., Ren, C., Zhang, L., Wang, C., Huang, K. and Lu, B. (2021), "A model of bead size based on the dynamic response of CMT-based wire and arc additive manufacturing process parameters", Rapid Prototyping Journal, Vol. 27 No. 4, pp. 741-753. https://doi.org/10.1108/RPJ-03-2020-0051

Publisher

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Emerald Publishing Limited

Copyright © 2021, Emerald Publishing Limited

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