A lumped-parameter, analytical model of material and thermal transfer is established in this paper for metal deposition by a moving, concentrated source. This is a dynamic description of the distinct width, height, length, and temperature of the ellipsoidal molten puddle, expressed with respect to the torch power, material feed and angle, and the source motion. This is established through scalar mass, momentum and energy balances of the puddle control volume, and thermal conduction in the substrate. The model is validated by GMA welding experiments, through measurements by an infrared camera and a laser profilometry scanner. These sensors are next employed for real-time identification of the model efficiency parameters, and for output feedback in a closed-loop geometry control system. Because of sensor delays, the model is run in-process to provide substitute estimates to the controller in a Smith predictor scheme. Closed-loop testing was conducted for control of the bead cross section profile through the torch velocity, and the applicability of such geometry regulation to solid freeform fabrication is discussed.
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February 2001
Technical Papers
Geometry Modeling and Control by Infrared and Laser Sensing in Thermal Manufacturing with Material Deposition
Charalabos Doumanidis,
Charalabos Doumanidis
Department of Mechanical Engineering, Tufts University, Medford, MA 02155
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Yong-Min Kwak
Yong-Min Kwak
Department of Mechanical Engineering, Tufts University, Medford, MA 02155
Search for other works by this author on:
Charalabos Doumanidis
Department of Mechanical Engineering, Tufts University, Medford, MA 02155
Yong-Min Kwak
Department of Mechanical Engineering, Tufts University, Medford, MA 02155
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received February 1999; revised March 2000. Associate Editor: R. Furness.
J. Manuf. Sci. Eng. Feb 2001, 123(1): 45-52 (8 pages)
Published Online: March 1, 2000
Article history
Received:
February 1, 1999
Revised:
March 1, 2000
Citation
Doumanidis , C., and Kwak, Y. (March 1, 2000). "Geometry Modeling and Control by Infrared and Laser Sensing in Thermal Manufacturing with Material Deposition ." ASME. J. Manuf. Sci. Eng. February 2001; 123(1): 45–52. https://doi.org/10.1115/1.1344898
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