Enhancing the Shape Complexity in Direct Energy Deposition with Phased Deformation

Gudur, Srinath and Simhambhatla, Suryakumar and Reddy, N Venkata (2022) Enhancing the Shape Complexity in Direct Energy Deposition with Phased Deformation. International Journal of Automation Technology, 16 (5). pp. 642-653. ISSN 1881-7629

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Wire-based direct energy deposition (W-DED) techniques in metal additive manufacturing allow partfabrication at higher deposition rates and lower costs. Given the lack of any support mechanism, these processes face challenges in fabricating overhanging features. The inherent overhang capability of weldbeads and higher-order kinematics can help realize certain complex geometries. However, significant challenges like non-uniform slicing, constrained deposition-torch accessibility, etc., limit the efficacy of these approaches. The present work describes a deformation-aided deposition process designed to overcome some of these limitations and to manufacture complex metallic components. It is based on a sequential combination of deposition and bending processes: a shape fabricated through W-DED deposition is bent to form the required shape. The cycle of deposition and bending is repeated until the final desired geometry is realized. The anisotropic and deterministic behaviors of the deposited components are analyzed in terms of springback and the punch force. Finally, the benefit of current hybrid process is demonstrated through a few illustrative geometries. © Fuji Technology Press Ltd.

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IITH Creators:
IITH CreatorsORCiD
Item Type: Article
Additional Information: This work was supported by Advanced Manufacturing Technology (AMT), Department of Science and Technology, New Delhi, India (sanction no. AMT/2017/082).
Uncontrolled Keywords: deformation aided deposition process; hybrid additive manufacturing processes; metal additive manufacturing; wire-based direct energy deposition (W-DED)
Subjects: Physics > Mechanical and aerospace
Divisions: Department of Mechanical & Aerospace Engineering
Depositing User: . LibTrainee 2021
Date Deposited: 20 Sep 2022 07:19
Last Modified: 20 Sep 2022 07:19
URI: http://raiith.iith.ac.in/id/eprint/10628
Publisher URL: http://doi.org/10.20965/ijat.2022.p0642
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