Masoodi Nia, Marzieh (2024) Adaptive Correction Strategy in Robotic Gas Tungsten Arc Welding for Additive Manufacturing. Masters thesis, Concordia University.
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Abstract
Wire arc additive manufacturing (WAAM) is one of additive manufacturing (AM) methods and owns notable advantages like enabling production of large-scale components. However, the current WAAM has inherent drawbacks, such as heat accumulation and near-net-shape production issues that can lead to defects like geometrical deviations, porosity inside the weld and/or surface irregularities. It is noted that various process parameters are directly related to the above-mentioned production issues. Therefore, it is crucial to set various process parameters (based on geometry, processing changes when depositing, etc.) appropriately for achieving a good quality of product
In this project, we aimed to investigate the influence of various process parameters on the product quality and to automate the WAAM process using a vision system. To realize the objectives, we have developed an adaptive correction strategy to control the robotic welding machine, i.e. a Nertamatic power source that centralize the welding cycle while considering various welding parameters such as the robot path, deposited layer height, surface contamination, etc. To minimize operator intervention, a Cognex 3D A5000 series camera was employed to scan/monitor the deposited object layer by layer. The camera’s ASCII output was used for mesh processing. An on-line control scheme has been developed to control the robot path according to the dimensions of previous layers and thus the robot’s height was adaptively adjusted. An algorithm was proposed to process the mesh data to detect and correct the inconsistencies by commanding the robot to stop in case of collisions or fill cavities in the case of insufficient height or underfills.
An experiment has been designed on a robotic WAAM machine where a TopTig gun was attached to the end effector of a 6-degree-of-freedom (DOF) ABB robot IRB4600, equipped with a 2-DOF IRBP_A500 table, to deposit material layer by layer. A nozzle is mounted with different diameter tungsten electrodes and fed with various wire materials. In this study, we tested a 3 mm diameter tungsten electrode and stainless-steel filler wire to assess the effects of overlap between the beads on the integrity of the deposited part. Simulations have been conducted in RobotStudio software to validate the recognizing deposited layer inconsistencies and the effectiveness of the path planning and welding machine settings, demonstrating the potential for deploying the adaptive correction strategy in the WAAM process.
| Divisions: | Concordia University > Gina Cody School of Engineering and Computer Science > Mechanical, Industrial and Aerospace Engineering |
|---|---|
| Item Type: | Thesis (Masters) |
| Authors: | Masoodi Nia, Marzieh |
| Institution: | Concordia University |
| Degree Name: | M.A. Sc. |
| Program: | Mechanical Engineering |
| Date: | 19 August 2024 |
| Thesis Supervisor(s): | Xie, Wen-Fang and Gholipour Baradari, Javad |
| Keywords: | Wire Arc Additive Manufacturing, Additive Manufacturing, Robotic Welding, Vision System, Direct Energy Deposition |
| ID Code: | 994632 |
| Deposited By: | Marzieh Masoodi Nia |
| Deposited On: | 24 Oct 2024 18:27 |
| Last Modified: | 24 Oct 2024 18:27 |
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