Abstract
Wire and arc additive manufacturing (WAAM) shows a great promise for fabricating fully dense metal parts by means of melting materials in layers using a welding heat source. However, due to a large layer height produced in WAAM, an unsatisfactory surface roughness of parts processed by this technology has been a key issue. A methodology based on laser vision sensing is proposed to quantitatively calculate the surface roughness of parts deposited by WAAM. Calibrations for a camera and a laser plane of the optical system are presented. The reconstruction precision of the laser vision system is verified by a standard workpiece. Additionally, this determination approach is utilized to calculate the surface roughness of a multi-layer single-pass thin-walled part. The results indicate that the optical measurement approach based on the laser vision sensing is a simple and effective way to characterize the surface roughness of parts deposited by WAAM. The maximum absolute error is less than 0.15 mm. The proposed research provides the foundation for surface roughness optimization with different process parameters.
Highlights
As opposed to traditional subtractive manufacturing process, additive manufacturing is an advanced technology for building complicated parts directly from a threedimensional (3D) model, by depositing materials in the form of powder or wire [1]
Publications in wire and arc additive manufacturing (WAAM) are mainly focused on several aspects, such as forming technology [2, 3, 6,7,8, 12], layer geometry optimization [10, 11], sensing and control of layer geometry [14, 15], microstructure and mechanical property [2, 6], evolution of temperature distribution and residual stress [16, 17], etc
This paper aims at establishing an approach for modeling the surface roughness, the reconstruction of which is realized through an optical system consisting of a camera and a diode laser
Summary
As opposed to traditional subtractive manufacturing process, additive manufacturing is an advanced technology for building complicated parts directly from a threedimensional (3D) model, by depositing materials in the form of powder or wire [1]. Aiming at a higher deposition rate and a lower cost, wire and arc additive manufacturing (WAAM) has been demonstrated to be a powerful process for fabricating metallic parts. Based on the surface profile given, a schematic diagram shown in Figure 3 can be conducted to present the surface roughness of parts deposited by WAAM.
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