Multi-Objective Accelerated Process Optimization of Part Geometric Accuracy in Additive Manufacturing

[+] Author and Article Information
Amir M. Aboutaleb

Industrial and Systems Engineering Department, Mississippi State University, MS, USA

Mark A. Tschopp

U.S. Army Research Laboratory, MD, USA

Prahalad K. Rao

Department of Mechanical and Materials Engineering, University of Nebraska-Lincoln, NE, USA

Linkan Bian

Industrial and Systems Engineering Department, Mississippi State University, MS, USA

1Corresponding author.

ASME doi:10.1115/1.4037319 History: Received December 17, 2016; Revised July 10, 2017


Despite recent advances in improving mechanical properties of parts fabricated by Additive Manufacturing (AM) systems, optimizing geometry accuracy of AM parts is still a major challenge for pushing this cutting-edge technology into the mainstream. This work proposes a novel approach for improving geometry accuracy of AM parts in a systematic and efficient manner. The proposed methodology formulates the geometric accuracy optimization problem as a multi-objective optimization problem. The developed method targeted at minimizing deviations within parts' major Geometric Dimensioning and Tolerancing (GD&T) features (i.e. Flatness, Circularity, Cylindricity, Concentricity and Thickness) from design specifications. The efficiency of proposed method is validated by conducting a real world case study for geometric accuracy optimization of parts fabricated by Fused Filament Fabrication (FFF) system. The results show that optimal designs are achieved by our methodology with fewer number of experiments compared with Full Factorial Design. Furthermore, we tested robustness of the proposed method via simulation studies. The proposed methodology is applied to test problems with various challenging characteristics such as non-convex Pareto front and congested design space, to name but a few. Simulation results and performance measures prove that the quality of Pareto front achieved by the proposed methodology is significantly higher compared with those resulted from Taguchi Design.

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