Abstract
Directed energy deposition (DED) irradiates a laser beam on a metal surface making a melt pool and supplies metal powder onto the pool to model a three-dimensional shape. The process requires keeping the optimum standoff distance (SOD) between the nozzle and a melt pool for achieving high-accuracy, -efficiency, and -quality modeling. However, it is difficult to optimally maintain the SOD because of complicated parameters in DED processes. In this study, three systems are developed for high-accuracy, -efficiency, and -quality modeling by DED. The first system measures the SOD in-process using a CMOS camera. The second generates modeling paths to model the N+1th layer according to the measured SOD of the Nth layer during the modeling of the Nth layer. The third generates an NC program using the generated modeling paths in real time and models a target object. The effectiveness of the total system was confirmed through verification experiments.
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