Physics-Based Multivariable Modeling and Feedback Linearization Control of Melt-Pool Geometry and Temperature in Directed Energy Deposition
Physics-Based Multivariable Modeling and Feedback Linearization Control of Melt-Pool Geometry and Temperature in Directed Energy Deposition
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DOI：
10.1115/1.4034304
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发表时间：
2017-02
影响因子：
4
通讯作者：
Qian Wang;Jianyi Li;M. Gouge;A. Nassar;P. Michaleris;E. Reutzel
中科院分区：
文献类型：
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作者：
Qian Wang;Jianyi Li;M. Gouge;A. Nassar;P. Michaleris;E. Reutzel
在文献中，人们一直在努力开发基于激光的附加制造(AM)过程的分析、数值和经验模型。然而，可以直接用于反馈控制设计的先进的基于物理的模型，即面向控制的模型，严重缺乏。在本文中，我们发展了一个基于物理的定向能沉积的多变量模型。我们的模型与现有工作的一个重要区别在于，对沉积过程中的材料传输速率作为工艺操作参数的函数进行了新的参数化。与现有的集总参数模型相比，这种参数化可以更好地描述稳态熔池几何结构。利用激光工程净成形(透镜)AM工艺沉积Ti-6Al-4V和Inconel®718获得的实验数据和有限元分析，验证了我们模型对熔池几何形状和温度的预测。然后基于该多变量模型，设计了一种非线性多输入多输出(MIMO)控制，特别是反馈线性化(FL)控制，利用激光功率和激光扫描速度跟踪熔池高度和温度参考轨迹。
There has been continuing effort in developing analytical, numerical, and empirical models of laser-based additive manufacturing (AM) processes in the literature. However, advanced physics-based models that can be directly used for feedback control design, i.e., control-oriented models, are severely lacking. In this paper, we develop a physics-based multivariable model for directed energy deposition. One important difference between our model from the existing work lies in a novel parameterization of the material transfer rate in the deposition as a function of the process operating parameters. Such parameterization allows an improved characterization of the steady-state melt-pool geometry compared to the existing lumped-parameter models. Predictions of melt-pool geometry and temperature from our model are validated using experimental data obtained from deposition of Ti-6AL-4V and deposition of Inconel®718 on a laser engineering net shaping (LENS) AM process and finite-element analysis. Then based on this multivariable model, we design a nonlinear multi-input multi-output (MIMO) control, specifically a feedback linearization (FL) control, to track both melt-pool height and temperature reference trajectories using laser power and laser scan speed.