A novel methodology to manufacture complex metallic sudden overhangs in weld-deposition based additive manufacturing

Simhambhatla, S (2023) A novel methodology to manufacture complex metallic sudden overhangs in weld-deposition based additive manufacturing. Rapid Prototyping Journal, 29 (2). ISSN 1355-2546

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Purpose: Amongst various additive manufacturing (AM) techniques for realizing the complex metallic objects, weld-deposition (arc)-based directed energy AM technique is attaining more focus over commercially available powder bed fusion techniques. This is because of the capability of high deposition rates, high power and material utilization, simpler setup and less initial investment of arc-based AM. Nevertheless, realization of sudden overhanging features through arc-based weld-deposition techniques is still a challenging task because of the necessity of support structures. This paper aims to describe a novel methodology for producing complex metallic objects with sudden overhangs without using supports. Design/methodology/approach: The realization of complex metallic objects with sudden overhangs (without using supports) is possible by reorienting the workpiece and/or deposition head at every instance using higher order kinematics (5-axis setup) to make sure the overhanging feature is in line to the deposition direction. Findings: In the absence of universally applicable support mechanism, deposition of overhanging features remains one of the main challenges in AM. A separate support structure is often necessary for depositing the overhanging features. Small overhang features are usually possible by a little overextension from the previous layer. Nevertheless, deposition of large gradually varying overhangs and sudden overhangs with complex features without support structures is a challenging task in any AM process. This demands higher order kinematics which calls for inclined and/or orthogonal slicing and area filling. Originality/value: The unique aspect of this paper is the identification of sudden overhang feature from a tessellated computer-aided design (.stl) file and generates an orthogonal tool path for deposition for sudden overhangs. An in-house MATLAB routine has been developed and presented for performing the same. This methodology helps in realization of sudden overhangs without use of supports. To validate proposed technique, various illustrative case studies have been taken up for deposition.

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IITH Creators:
IITH CreatorsORCiD
Simhambhatla, Shttp://orcid.org/0000-0001-6015-7593
Item Type: Article
Uncontrolled Keywords: Automated tool path generation; Metallic additive manufacturing; Orthogonal weld deposition; Sudden overhang features; Support mechanism; Automated tool path generation; Automated tools; Metallic additive manufacturing; Metallic additives; Metallic objects; Orthogonal weld deposition; Sudden overhang feature; Support mechanism; Toolpath generations; Weld deposition; Additives; Deposition rates; Ground supports; Investments; Kinematics; Metals; Welds; 3D printers
Subjects: Physics > Mechanical and aerospace
Physics > Mechanical and aerospace > Transportation Science & Technology
Divisions: Department of Mechanical & Aerospace Engineering
Depositing User: Mr Nigam Prasad Bisoyi
Date Deposited: 17 Aug 2023 04:34
Last Modified: 17 Aug 2023 04:34
URI: http://raiith.iith.ac.in/id/eprint/11563
Publisher URL: https://doi.org/10.1108/RPJ-08-2021-0215
OA policy: https://v2.sherpa.ac.uk/id/publication/2982
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