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Research Papers

Offline Predictive Control of Out-of-Plane Shape Deformation for Additive Manufacturing

[+] Author and Article Information
Yuan Jin

Mork Family Department of Chemical
Engineering and Materials Science,
University of Southern California,
Los Angeles, CA 90089
e-mail: yuanjin@usc.edu

S. Joe Qin

Mork Family Department of Chemical
Engineering and Materials Science,
University of Southern California,
Los Angeles, CA 90089
e-mail: sqin@usc.edu

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 July 26, 2015; final manuscript received April 10, 2016; published online July 25, 2016. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 138(12), 121005 (Jul 25, 2016) (7 pages) Paper No: MANU-15-1375; doi: 10.1115/1.4033444 History: Received July 26, 2015; Revised April 10, 2016

Additive manufacturing (AM) is a promising direct manufacturing technology, and the geometric accuracy of AM built products is crucial to fulfill the promise of AM. Prediction and control of three-dimensional (3D) shape deformation, particularly out-of-plane geometric errors of AM built products, have been a challenging task. Although finite-element modeling has been extensively applied to predict 3D deformation and distortion, improving part accuracy based purely on such simulation still needs significant methodology development. We have been establishing an alternative strategy that can be predictive and transparent to specific AM processes based on a limited number of test cases. Successful results have been accomplished in our previous work to control in-plane (x–y plane) shape deformation through offline compensation. In this study, we aim to establish an offline out-of-plane shape deformation control approach based on limited trials of test shapes. We adopt a novel spatial deformation formulation in which both in-plane and out-of-plane geometric errors are placed under a consistent mathematical framework to enable 3D accuracy control. Under this new formulation of 3D shape deformation, we develop a prediction and offline compensation method to reduce out-of-plane geometric errors. Experimental validation is successfully conducted to validate the developed 3D shape accuracy control approach.

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References

Figures

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Fig. 1

Shape deformation representation under polar coordinates

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Fig. 2

In-plane error of cylindrical parts with r0 = 0.5 in., 1 in., 2 in., and 3 in. [13]

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Fig. 3

In-plane deformation representation

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Fig. 4

Out-of-plane deformation representation

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Fig. 7

Prism case study: deformation profiles and model predictions. (a) Front and back side surfaces and (b) left and right side surfaces.

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Fig. 6

Prism case study: (a) printed rectangular prism part and (b) measured data of the prism right surface

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Fig. 5

Out-of-plane deformation definition

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Fig. 8

Modified cookie-cutter function

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Fig. 10

Prism case study: before and after compensation. (a) Front and back side surfaces and (b) left and right side surfaces.

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Fig. 9

Modified indicator function

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