Iterative Process Control for Laser Metal Deposition

激光金属沉积的迭代过程控制

• 批准号: 1301414
• 负责人: Douglas Bristow
• 金额: $ 27.29万
• 依托单位: Missouri University of Science and Technology
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2013
• 资助国家: 美国
• 起止时间: 2013-06-01 至 2017-05-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1301414&HistoricalAwards=false
• 关键词: Iterative; Process; Control; Laser; Metal

The research objective of this award is to develop robust, high-performance control algorithms for Laser Metal Deposition (LMD) processes. LMD is a class of additive manufacturing processes that builds metal parts layer by layer, introducing dynamics that propagate in time and also layer-domains. While conventional control strategies consider only the time-domain dynamics, the layer-domain dynamics introduce significant part defects that affect process reliability and efficiency. Physics-based 2-D (time- and layer-domain) dynamic models of the LMD process will be created and validated on a LMD machine at Missouri S&T and an industrial LMD machine at Optomec, Inc. New Repetitive Process Control (RPC) algorithms will be developed to control the 2-D LMD dynamics addressing issues of robustness and performance. The methodology employed may also be beneficial in other additive and layer-based manufacturing processes. This project will spur innovation in additive manufacturing by advancing the science, education, and practice of LMD process modeling and control, potentially leading to dramatic improvements in reliability, efficiency, and productivity. Additive manufacturing processes hold tremendous potential to transform the way parts are manufactured, away from multi-step hands-on fabrication, to single-step automation directly from CAD models. The LMD process in particular is a critically important additive manufacturing process because it is able to produce service-ready metal parts with little material waste, repair high-cost parts, and produce functional gradient material metal parts. The PI will develop an online distance course on repetitive process control. The investigators will involve undergraduates directly in the research activities through Missouri S&T undergraduate research programs and their existing REU Site in Additive Manufacturing. With the joint support of OIIS/ISE the PI and graduate students will collaborate with researchers in Poland to leverage expertise and facilities.

该奖项的研究目标是为激光金属沉积（LMD）工艺开发强大的高性能控制算法。 LMD 是一类增材制造工艺，可逐层构建金属零件，引入在时间和层域中传播的动力学。 虽然传统的控制策略仅考虑时域动态，但层域动态会引入影响过程可靠性和效率的重要零件缺陷。 将在 Missouri S&T 的 LMD 机器和 Optomec, Inc. 的工业 LMD 机器上创建和验证 LMD 过程的基于物理的 2-D（时域和层域）动态模型。将开发新的重复过程控制 (RPC) 算法来控制 2-D LMD 动态，解决鲁棒性和性能问题。 所采用的方法也可能有益于其他增材和基于层的制造工艺。该项目将通过推进 LMD 过程建模和控制的科学、教育和实践来刺激增材制造的创新，从而有可能显着提高可靠性、效率和生产力。增材制造工艺具有巨大的潜力，可以改变零件的制造方式，从多步骤的手动制造转变为直接从 CAD 模型实现单步骤自动化。 LMD 工艺尤其是一种极其重要的增材制造工艺，因为它能够生产出可立即使用的金属零件，且材料浪费极少，能够修复高成本零件，并生产功能梯度材料金属零件。 PI 将开发有关重复过程控制的在线远程课程。研究人员将通过密苏里科技本科生研究项目及其现有的增材制造 REU 站点，让本科生直接参与研究活动。 在 OIIS/ISE 的共同支持下，PI 和研究生将与波兰的研究人员合作，利用专业知识和设施。