Browse > Article
http://dx.doi.org/10.12989/sss.2022.29.6.767

In situ monitoring-based feature extraction for metal additive manufacturing products warpage prediction  

Lee, Jungeon (Department of Industrial Engineering, Sungkyunkwan University)
Baek, Adrian M. Chung (Department of Mechanical Engineering, Ulsan National Institute of Science and Technology)
Kim, Namhun (Department of Mechanical Engineering, Ulsan National Institute of Science and Technology)
Kwon, Daeil (Department of Industrial Engineering, Sungkyunkwan University)
Publication Information
Smart Structures and Systems / v.29, no.6, 2022 , pp. 767-775 More about this Journal
Abstract
Metal additive manufacturing (AM), also known as metal three-dimensional (3D) printing, produces 3D metal products by repeatedly adding and solidifying metal materials layer by layer. During the metal AM process, products experience repeated local melting and cooling using a laser or electron beam, resulting in product defects, such as warpage, cracks, and internal pores. Such defects adversely affect the final product. This paper proposes the in situ monitoring-based warpage prediction of metal AM products with experimental feature extraction. The temperature profile of the metal AM substrate during the process was experimentally collected. Time-domain features were extracted from the temperature profile, and their relationships to the warpage mechanism were investigated. The standard deviation showed a significant linear correlation with warpage. The findings from this study are expected to contribute to optimizing process parameters for metal AM warpage reduction.
Keywords
experimental validation; feature extraction; in situ monitoring; metal additive manufacturing; warpage prediction;
Citations & Related Records
Times Cited By KSCI : 3  (Citation Analysis)
연도 인용수 순위
1 Lee, J. and Chung, H. (2020), "Experimental investigation of deposition pattern on the temperature and distortion of direct energy deposition-based additive manufactured part", Appl. Sci., 10(21), 7653. https://doi.org/10.3390/app10217653.   DOI
2 Lee, Y., Lee, S., Zhao, X.G., Lee, D., Kim, T., Jung, H. and Kim, N. (2018), "Impact of UV curing process on mechanical properties and dimensional accuracies of digital light processing 3D printed objects", Smart Struct. Syst., 22(2), 161-166. https://doi.org/10.12989/sss.2018.22.2.161.   DOI
3 Li, C., Liu, Z.Y., Fang, X.Y. and Guo, Y.B. (2018), "Residual stress in metal additive manufacturing", Procedia Cirp, 71, 348-353. https://doi.org/10.1016/j.procir.2018.05.039.   DOI
4 Paul, R., Anand, S. and Gerner, F. (2014), "Effect of thermal deformation on part errors in metal powder based additive manufacturing processes", J. Manuf. Sci. Eng., 136(3), 031009. https://doi.org/10.1115/1.4026524.   DOI
5 Rubino, F., Astarita, A. and Carlone, P. (2018), "Thermomechanical finite element modeling of the laser treatment of titanium cold-sprayed coatings", Coating., 8(6), 219. https://doi.org/10.3390/coatings8060219.   DOI
6 Shi, Y., Yao, Z., Shen, H. and Hu, J. (2006), "Research on the mechanisms of laser forming for the metal plate", Int. J. Mach. Tool. Manuf., 46(12-13), 1689-1697. https://doi.org/10.1016/j.ijmachtools.2005.09.016.   DOI
7 Mageshwaran, G., Polisetti, S.R., Jeevahan, J. and Joseph, G.B. (2017), "Enhancement of uniform temperature distribution during casting solidification by methoding process", Int. J. Ambient Energy, 38(8), 774-780. https://doi.org/10.1080/01430750.2016.1222959.   DOI
8 Dastjerdi, A.A., Movahhedy, M.R. and Akbari, J. (2017), "Optimization of process parameters for reducing warpage in selected laser sintering of polymer parts", Add. Manuf., 18, 285-294. https://doi.org/10.1016/j.addma.2017.10.018.   DOI
9 Desai, P.D. and Ho, C.Y. (1978), "Thermal linear expansion of nine selected AISI stainless steels", Thermophysical and Electronic Properties Information Analysis Center Lafayette In.
10 Frazier, W.E. (2014), "Metal additive manufacturing: A review", J. Mater. Eng. Perform., 23(6), 1917-1928. https://doi.org/10.1007/s11665-014-0958-z.   DOI
11 Gere, J.M. and Goodno, B.J. (2009), Mechanics of Materials, Cengage Learning. Inc., Independence, KY.
12 Kim, Y.W. and Jewong, W.B. (2020), "Defect classification of refrigerant compressor using variance estimation of the transfer function between pressure pulsation and shell acceleration", Smart Struct. Syst., 25(2), 255-264. https://doi.org/10.12989/sss.2020.25.2.255.   DOI
13 Arnold, C. and Korner, C. (2021), "In-situ electron optical measurement of thermal expansion in electron beam powder bed fusion", Add. Manuf., 46, 102213. https://doi.org/10.1016/j.addma.2021.102213.   DOI
14 Bian, P., Shi, J., Liu, Y. and Xie, Y. (2020), "Influence of laser power and scanning strategy on residual stress distribution in additively manufactured 316L steel", Optic. Las. Technol., 132, 106477. https://doi.org/10.1016/j.optlastec.2020.106477.   DOI
15 Caltanissetta, F., Grasso, M., Petro, S. and Colosimo, B.M. (2018), "Characterization of in-situ measurements based on layerwise imaging in laser powder bed fusion", Add. Manuf., 24, 183-199. https://doi.org/10.1016/j.addma.2018.09.017.   DOI
16 Kyrsanidi, A.K., Kermanidis, T.B. and Pantelakis, S.G. (2000), "An analytical model for the prediction of distortions caused by the laser forming process", J. Mater. Proc. Technol., 104(1-2), 94-102. https://doi.org/10.1016/S0924-0136(00)00520-3.   DOI
17 Venkatkumar, D. and Ravindran, D. (2016), "3D finite element simulation of temperature distribution, residual stress and distortion on 304 stainless steel plates using GTA welding", J. Mech. Sci. Technol., 30(1), 67-76. https://doi.org/10.1007/s12206-015-1208-5.   DOI
18 Choi, T.Y. (2020), "Machine learning based predictive modeling of dimensional quality in direct energy deposition with SUS316L", Graduate School of UNIST.
19 Foroozmehr, E. and Kovacevic, R. (2010), "Effect of path planning on the laser powder deposition process: Thermal and structural evaluation", Int. J. Adv. Manuf. Technol., 51(5), 659-669. https://doi.org/10.1007/s00170-010-2659-6.   DOI
20 Khanzadeh, M., Chowdhury, S., Marufuzzaman, M., Tschopp, M.A. and Bian, L. (2018), "Porosity prediction: Supervised-learning of thermal history for direct laser deposition", J. Manuf. Syst., 47, 69-82. https://doi.org/10.1016/j.jmsy.2018.04.001.   DOI
21 Lewandowski, J.J. and Seifi, M. (2016), "Metal additive manufacturing: A review of mechanical properties", Ann. Rev. Mater. Res., 46, 151-186. https://doi.org/10.1146/annurevmatsci-070115-032024.   DOI
22 Matsunawa, A., Mizutani, M., Katayama, S. and Seto, N. (2003), "Porosity formation mechanism and its prevention in laser welding", Weld. Int., 17(6), 431-437. https://doi.org/10.1533/wint.2003.3138.   DOI
23 Sanchez, R., Aisa, J., Martinez, A. and Mercado, D. (2012), "On the relationship between cooling setup and warpage in injection molding", Measure., 45(5), 1051-1056. https://doi.org/10.1016/j.measurement.2012.01.039.   DOI
24 Srivastava, S., Garg, R.K., Sharma, V.S. and Sachdeva, A. (2021), "Measurement and mitigation of residual stress in wire-arc additive manufacturing: A review of macro-scale continuum modelling approach", Arch. Comput. Meth. Eng., 28(5), 3491-3515. https://doi.org/10.1007/s11831-020-09511-4.   DOI
25 Zhang, Z., Liu, Z. and Wu, D. (2021), "Prediction of melt pool temperature in directed energy deposition using machine learning", Add. Manuf., 37, 101692. https://doi.org/10.1016/j.addma.2020.101692.   DOI
26 Zeng, C., Tian, W., Liao, W.H. and Hua, L. (2016), "Microstructure and porosity evaluation in laser-cladding deposited Ni-based coatings", Surf. Coating. Technol., 294, 122-130. https://doi.org/10.1016/j.surfcoat.2016.03.083.   DOI
27 Sim, J., Kim, S., Park, H.J. and Choi, J.H. (2020), "A tutorial for feature engineering in the prognostics and health management of gears and bearings", Appl. Sci., 10(16), 5639. https://doi.org/10.3390/app10165639.   DOI
28 Stavropoulos, P. and Foteinopoulos, P. (2018), "Modelling of additive manufacturing processes: A review and classification", Manuf. Rev., 5, 2. https://doi.org/10.1051/mfreview/2017014.   DOI
29 Vafadar, A., Guzzomi, F., Rassau, A. and Hayward, K. (2021), "Advances in metal additive manufacturing: A review of common processes, industrial applications, and current challenges", Appl. Sci., 11(3), 1213. https://doi.org/10.3390/app11031213.   DOI
30 Wang, H., Zhu, Q., Li, J., Mao, J., Hu, S. and Zhao, X. (2019), "Identification of moving train loads on railway bridge based on strain monitoring", Smart Struct. Syst., 23(3), 263-278. https://doi.org/10.12989/sss.2019.23.3.263.   DOI
31 Kumar, L.J. and Krishnadas Nair, C.G. (2017), "Current trends of additive manufacturing in the aerospace industry", Advances in 3D Printing & Additive Manufacturing Technologies, Springer, Singapore.