Fabrication Guideline for Wire Arc Additive Manufacturing
Azadikhah, Aaron (2023)
2023
Konetekniikan DI-ohjelma - Master's Programme in Mechanical Engineering
Tekniikan ja luonnontieteiden tiedekunta - Faculty of Engineering and Natural Sciences
This publication is copyrighted. You may download, display and print it for Your own personal use. Commercial use is prohibited.
Hyväksymispäivämäärä
2023-11-20
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tuni-202311159682
https://urn.fi/URN:NBN:fi:tuni-202311159682
Tiivistelmä
Sustainable manufacturing goals require production activities to reduce the usage of energy, material, and reduce emissions. Additive manufacturing has shown capabilities to reduce on energy and material usage. Among the various types of additive manufacturing, Wire Arc Additive Manufacturing (WAAM) stands out as a reliable alternative for manufacturing metallic components, especially bulky ones. This method is particularly intriguing when it comes to producing components in the aerospace industry. Furthermore, the equipment required for this technique is cost-effective in comparison to other methods.
The thesis aims to compile comprehensive information on the equipment used by the Manufacturing Systems Research Group at Tampere University. This compilation includes detailed explanations related to the pre-processing steps, the necessary software usage instructions, supported by an example, and the utilization of the ABB robot. The thesis delves into the majority of critical theories associated with WAAM, such as the welding parameters, and weld bead geometry. It is worth mentioning that the theoretical aspects are limited due to the extensive nature of WAAM research domain, which makes comprehensive analysis infeasible.
The research involves three case studies aimed at providing in-depth analysis and discussion on various aspects of WAAM. Two primary research questions guide the thesis. The first question seeks to identify and develop a general path planning approach for implementing the WAAM technique. The second question revolves around identifying influential factors and path planning strategies to enhance part geometry.
In parallel with the general preprocessing, we successfully utilized another alternative to implement the process. It involved the creation of Rapid code for continuous welding with varying welding parameters, resulting in different deposition rates during welding. Furthermore, the utilization of Siemens NX has brought its own set of advantages. From a practical standpoint, the pre-processing phase requires less time, and simulation becomes more straightforward. Moreover, Siemens NX includes its own path planning functionality, further enhancing its overall utility. Regarding the second research question, the thesis achieved substantial success in devising suitable path planning for infill in bulky parts. Additionally, different path planning approaches were explored for printing cross-shaped walls, with the thesis identifying the most effective method for manufacturing such walls.
The thesis aims to compile comprehensive information on the equipment used by the Manufacturing Systems Research Group at Tampere University. This compilation includes detailed explanations related to the pre-processing steps, the necessary software usage instructions, supported by an example, and the utilization of the ABB robot. The thesis delves into the majority of critical theories associated with WAAM, such as the welding parameters, and weld bead geometry. It is worth mentioning that the theoretical aspects are limited due to the extensive nature of WAAM research domain, which makes comprehensive analysis infeasible.
The research involves three case studies aimed at providing in-depth analysis and discussion on various aspects of WAAM. Two primary research questions guide the thesis. The first question seeks to identify and develop a general path planning approach for implementing the WAAM technique. The second question revolves around identifying influential factors and path planning strategies to enhance part geometry.
In parallel with the general preprocessing, we successfully utilized another alternative to implement the process. It involved the creation of Rapid code for continuous welding with varying welding parameters, resulting in different deposition rates during welding. Furthermore, the utilization of Siemens NX has brought its own set of advantages. From a practical standpoint, the pre-processing phase requires less time, and simulation becomes more straightforward. Moreover, Siemens NX includes its own path planning functionality, further enhancing its overall utility. Regarding the second research question, the thesis achieved substantial success in devising suitable path planning for infill in bulky parts. Additionally, different path planning approaches were explored for printing cross-shaped walls, with the thesis identifying the most effective method for manufacturing such walls.