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Research Papers

An Analytical Foundation for Optimal Compensation of Three-Dimensional Shape Deformation in Additive Manufacturing

[+] Author and Article Information
Qiang Huang

Associate Professor and Gordon S. Marshall
Early Career Chair in Engineering
Daniel J. Epstein Department of Industrial and Systems Engineering,
University of Southern California,
Los Angeles, CA 90089
e-mail: qiang.huang@usc.edu

Manuscript received September 14, 2015; final manuscript received December 7, 2015; published online January 12, 2016. Assoc. Editor: Z. J. Pei.

J. Manuf. Sci. Eng 138(6), 061010 (Jan 12, 2016) (8 pages) Paper No: MANU-15-1480; doi: 10.1115/1.4032220 History: Received September 14, 2015; Revised December 07, 2015

Additive manufacturing (AM) or three-dimensional (3D) printing is a promising technology that enables the direct fabrication of products with complex shapes without extra tooling and fixturing. However, control of 3D shape deformation in AM built products has been a challenging issue due to geometric complexity, product varieties, material phase changing and shrinkage, and interlayer bonding. One viable approach for accuracy control is through compensation of the product design to offset the geometric shape deformation. This work provides an analytical foundation to achieve optimal compensation for high-precision AM. We first present the optimal compensation policy or the optimal amount of compensation for two-dimensional (2D) shape deformation. By analyzing its optimality property, we propose the minimum area deviation (MAD) criterion to offset 2D shape deformation. This result is then generalized by establishing the minimum volume deviation (MVD) criterion and by deriving the optimal amount of compensation for 3D shape deformation. Furthermore, MAD and MVD criteria provide convenient quality measure or quality index for AM built products that facilitate online monitoring and feedback control of shape geometric accuracy.

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Copyright © 2016 by ASME
Topics: Deformation , Shapes
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Figures

Grahic Jump Location
Fig. 2

Transform shape deformation to deviation profiles in the PCS

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Fig. 3

Multiple profiles and PCSs

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Fig. 4

Shape area deviation before (a) and after (b) compensation

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Fig. 5

In-plane errors of cylindrical parts with r0=0.5, 1, 2, and 3 in. [20]

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Fig. 6

Predictive validation for 2.5 in. cylinder

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Fig. 7

In-plane deformation representation

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Fig. 8

Out-of-plane deformation representation

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Fig. 9

Volume deviation at location (θ,φ)

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Fig. 10

Compensation at φ=0,π/2

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