Selection of Process Parameters for Near-Net Shape Deposition in Wire Arc Additive Manufacturing by Genetic Algorithm
Selection of Process Parameters for Near-Net Shape Deposition in Wire Arc Additive Manufacturing by Genetic Algorithm
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DOI：
10.1007/s11665-020-04847-1
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发表时间：
2020-05-20
影响因子：
2.3
通讯作者：
Maji, Kuntal
中科院分区：
文献类型：
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作者：
Kumar, Ashish;Maji, Kuntal
在焊丝电弧添加剂制造(WAAM)中，任何元件的制造都需要在多层中沉积多个珠子。本文提出了用遗传算法优化近净形状沉积参数的方法，以最小化WAAM中的空洞和多余材料。首先，利用响应面方法建立了单珠的几何模型，并利用Box-Behenken设计的实验设计对WAAM中的304L不锈钢进行了沉积实验。用电压、送丝速度、焊炬速度和气体流量等工艺参数来表示焊珠的几何参数，即焊道宽度、焊道高度和焊道横截面积等。利用遗传算法确定了最优的工艺条件和沉积计划，以最小化空隙和最大化材料产量。通过对切片、墙体和块体三种形状的沉积实验，验证了该方法的有效性。在最佳工艺参数下制备的三种形状具有最小的孔洞和最大的材料屈服。结果表明，对于不同的几何形状，最佳的微珠尺寸和重叠度是不同的。对沉积材料的力学测试和金相表征表明，沉积材料的性能与母材的性能相当。此外，与单丝进给沉积相比，双丝进给沉积具有更高的沉积速率和更好的力学性能。
In wire arc additive manufacturing (WAAM), deposition of multiple beads in multiple layers is required for fabricating any component. This article presents ways to optimize the selection of parameters for near-net shape deposition to minimize void and excess material in WAAM by GA. Initially single-bead geometry model was developed utilizing response surface methodology and experiments were conducted utilizing Box-Behenken design of experiments for deposition of 304L stainless steel in WAAM. Bead geometry parameters, i.e., bead width, bead height and bead cross-sectional area, etc., were expressed in terms of the process parameters like voltage, wire feed rate, torch speed and gas flow rate. Optimal processing conditions and deposition planning were determined utilizing a GA to minimize void and maximize material yield. The proposed approach was validated through deposition of three shapes, i.e., slice, wall and block. The three shapes fabricated with optimal parameters were found to have minimum void and maximum material yield. It has been revealed that optimal bead sizes and degree of overlapping are different for fabricating different geometries. Mechanical testing and metallurgical characterization of the deposited materials exhibited comparable properties of the deposited material to that of the base material. Moreover, double wire feed deposition was seen to deliver higher deposition rate and superior mechanical properties of the deposited material compared to the single wire feed deposition.