Abstract
Surface accuracy directly affects the surface quality and performance of mechanical parts. Circular hole, especially spatial non-planar hole set is the typical feature and working surface of mechanical parts. Compared with traditional machining methods, additive manufacturing (AM) technology can decrease the surface accuracy errors of circular holes during fabrication. However, an accuracy error may still exist on the surface of circular holes fabricated by AM due to the influence of staircase effect. This study proposes a surface accuracy optimization approach for mechanical parts with multiple circular holes for AM based on triangular fuzzy number (TFN). First, the feature lines on the manifold mesh are extracted using the dihedral angle method and normal tensor voting to detect the circular holes. Second, the optimal AM part build orientation is determined using the genetic algorithm to optimize the surface accuracy of the circular holes by minimizing the weighted volumetric error of the part. Third, the corresponding weights of the circular holes are calculated with the TFN analytic hierarchy process in accordance with the surface accuracy requirements. Lastly, an improved adaptive slicing algorithm is utilized to reduce the entire build time while maintaining the forming surface accuracy of the circular holes using digital twins via virtual printing. The effectiveness of the proposed approach is experimentally validated using two mechanical models.
Highlights
Circular hole, especially spatial non-planar hole set is the typical feature and working surface of mechanical parts
Jinghua XU et al Surface accuracy optimization of mechanical parts with multiple circular holes et al [29] presented a feature line recognition method that uses the normal tensor voting technique to estimate the curvature in large-scale and noisy grids
The current work attempts to optimize the surface accuracy of the circular holes of mechanical parts fabricated by additive manufacturing (AM) by using an optimal part build orientation and an appropriate slicing algorithm
Summary
Especially spatial non-planar hole set is the typical feature and working surface of mechanical parts. The selection of the part build orientation and slicing algorithm is crucial in improving the surface accuracy of the circular holes of a part fabricated by AM because the SE of a part fabricated by AM is generally difficult to be eliminated. Kim. Jinghua XU et al Surface accuracy optimization of mechanical parts with multiple circular holes et al [29] presented a feature line recognition method that uses the normal tensor voting technique to estimate the curvature in large-scale and noisy grids. The current work attempts to optimize the surface accuracy of the circular holes of mechanical parts fabricated by AM by using an optimal part build orientation and an appropriate slicing algorithm.
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