Physics-Based Multivariable Modeling and Feedback Linearization Control of Melt-Pool Geometry and Temperature in Directed Energy Deposition
Open Access
- 21 September 2016
- journal article
- research article
- Published by ASME International in Journal of Manufacturing Science and Engineering
- Vol. 139 (2)
- https://doi.org/10.1115/1.4034304
Abstract
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.Keywords
Funding Information
- Office of Naval Research (N00014-11-1-0668)
This publication has 44 references indexed in Scilit:
- Toward an integrated computational system for describing the additive manufacturing process for metallic materialsAdditive Manufacturing, 2014
- Computational modelling of shaped metal depositionInternational Journal for Numerical Methods in Engineering, 2010
- An Integrated Model to Simulate Laser Cladding Manufacturing Process for Engine Repair ApplicationsWelding in the World, 2010
- A three-dimensional finite element analysis of the temperature field during laser melting of metal powders in additive layer manufacturingInternational Journal of Machine Tools and Manufacture, 2009
- Rapid manufacturing of metal components by laser formingInternational Journal of Machine Tools and Manufacture, 2006
- Direct tool steel injection mould inserts through the Arcam EBM free‐form fabrication processAssembly Automation, 2005
- The role of process variables in laser-based direct metal solid freeform fabricationJOM, 2001
- Understanding thermal behavior in the LENS processMaterials & Design (1980-2015), 1999
- Producing metal parts with selective laser sintering/hot isostatic pressingJOM, 1998
- Innovative Laser-Aided Manufacturing of Patterned Stamping and Cutting Dies: Processing ParametersMaterials and Manufacturing Processes, 1998