Bead Geometry Prediction in Laser-Wire Additive Manufacturing Process Using Machine Learning: Case of Study
Abstract
:Featured Application
Abstract
1. Introduction
2. Methodology
- Parametric surface creation: In this step, mathematical tools are used to create a 2D model surface. Alternatively, a CAD part could be imported directly and changed to a parametric CAD part using Grasshoppers tools.
- Pattern creation: In this step, patterns (zigzag, spiral tool path, etc.) are designed and added to the 2D surface. The zigzag pattern is advised for its simplicity of implementation, robustness, and surface roughness [40].
- Layer-to-layer deposition strategy: After depositing the first layer, a suitable travel strategy is required to reach the next layer, and successively. The travel strategy depends on some deposition parameters, such as the laser power, wire feed rate, and robot travel speed. Therefore, the travel strategy should be carefully chosen as it can influence the cooling of the previous layer as well as the bonding between layers. For more details see e.g., [41,42].
- Bead geometry measurements: Finally, a laser scanner was used to obtain the measurements data of the bead geometry during the LWAM process. The laser scanner was mounted on the welding robot’s arm to directly measure the bead geometry for each layer deposition. A measurement for a single bead geometry and layer deposition is shown in Figure 3.
3. Prediction Model
3.1. Bead Height Prediction Model
3.2. Neural Network Prediction
4. Experimental Results and Discussion
4.1. Bead Geometry Prediction
4.2. First-Order Deposition Parameters
5. Conclusions
- Regression algorithms can be used for prediction tasks related to the LWAM process, including for supervision tasks;
- There exists a power decay in correlating process parameters to bead thickness.
- The experimental results showed an increase of width-to-height ratio as a function of layer progression due to the heat conducted from the laser–matter interaction.
- Satisfying prediction models were obtained and could be used to predict the geometry of beads as part of LWAM control programming for horizontal and vertical robot movement.
- In this case, acceptable bead prediction with good layer deposition was obtained when P, V, and F were kW, m/min, and m/min, respectively.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Test Trial | P (kW) | F (m/min) | V (m/min) |
---|---|---|---|
Sample 1 | 1.6 | 0.6 | 2.0 |
Sample 2 | 1.6 | 0.3 | 2.2 |
Sample 3 | 2.0 | 0.9 | 2.2 |
Sample 4 | 1.6 | 1.2 | 2.2 |
Sample 5 | 1.4 | 1.4 | 0.45 |
Sample | RMSE | MAE | MAPE | |||||
---|---|---|---|---|---|---|---|---|
Height | Width | Height | Width | Height | Width | Height | Width | |
1 | 0.0361 | 0.0337 | 0.9847 | 0.9894 | 0.0282 | 0.0082 | 2.8151% | 0.8235% |
2 | 0.0580 | 0.2053 | 0.9888 | 0.9242 | 0.0291 | 0.0301 | 2.9098% | 3.0145% |
3 | 0.0392 | 0.0154 | 0.9818 | 0.9652 | 0.0345 | 0.0037 | 3.4547% | 0.3704% |
4 | 0.0388 | 0.0094 | 0.9717 | 0.9300 | 0.0408 | 0.0030 | 4.0777% | 0.2951% |
5 | 0.0176 | 0.0258 | 0.9954 | 0.9947 | 0.0232 | 0.0047 | 2.3192% | 0.4720% |
P | V | F | |
---|---|---|---|
Acceptable bead Prediction | Low | Low | High |
Good layer Deposition | Low | Low | High |
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Mbodj, N.G.; Abuabiah, M.; Plapper, P.; El Kandaoui, M.; Yaacoubi, S. Bead Geometry Prediction in Laser-Wire Additive Manufacturing Process Using Machine Learning: Case of Study. Appl. Sci. 2021, 11, 11949. https://doi.org/10.3390/app112411949
Mbodj NG, Abuabiah M, Plapper P, El Kandaoui M, Yaacoubi S. Bead Geometry Prediction in Laser-Wire Additive Manufacturing Process Using Machine Learning: Case of Study. Applied Sciences. 2021; 11(24):11949. https://doi.org/10.3390/app112411949
Chicago/Turabian StyleMbodj, Natago Guilé, Mohammad Abuabiah, Peter Plapper, Maxime El Kandaoui, and Slah Yaacoubi. 2021. "Bead Geometry Prediction in Laser-Wire Additive Manufacturing Process Using Machine Learning: Case of Study" Applied Sciences 11, no. 24: 11949. https://doi.org/10.3390/app112411949
APA StyleMbodj, N. G., Abuabiah, M., Plapper, P., El Kandaoui, M., & Yaacoubi, S. (2021). Bead Geometry Prediction in Laser-Wire Additive Manufacturing Process Using Machine Learning: Case of Study. Applied Sciences, 11(24), 11949. https://doi.org/10.3390/app112411949