Models for the simulation of spray deposition and robot motion optimization in thermal spraying of rotating objects

Abstract

In this paper we consider methods to simulate deposit build-up in thermal spraying and to optimize the robot motion so as to obtain the desired layer thickness. We derive a simplified mathematical model for spray deposition on a rotating large object with a smooth, rotationally symmetric, curved surface, yet allowing varying spray distance and direction. Further, we discuss how to obtain and incorporate an empirically determined deposit rate model. In particular, the simplified spray deposition model is chosen to make possible a reasonably cheap method to approximate a deposit rate from the results of layer thickness measurements. We also propose an iterative method to obtain good initial values for robot feed optimization. Numerical examples are presented.