Time-dependent manufacturing processes lead to a new class of inverse problems

Axinte, Dragoş; Billingham, J.

doi:10.1073/pnas.1900420116

Cited by 18 publications

(5 citation statements)

References 10 publications

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“…The optimisation of such processes is typically time-consuming, especially if based on complex multi-physics models. To circumvent this problem, Axinte and Billingham [267] postulated an inverse problem-solving approach, where the input is a targeted surface to be created (e.g., laser polished), and the outputs are control parameters needed to achieve this surface. The extent to which the inverse-problem approach is adopted by researchers in the field is still limited, as the majority of beam modelling/optimisation approaches continue to be trial-and-error.…”

Section: Discussionmentioning

confidence: 99%

Post-processing of additively manufactured metallic alloys – A review

Malakizadi

Mallipeddi

Dadbakhsh

et al. 2022

International Journal of Machine Tools and Manufacture

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Section: Discussionmentioning

confidence: 99%

Post-processing of additively manufactured metallic alloys – A review

Malakizadi

Mallipeddi

Dadbakhsh

et al. 2022

International Journal of Machine Tools and Manufacture

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“…However, it has been shown for other dwell-time energy beam processes (e.g. waterjet milling, pulsed laser ablation, focused ion beam) [43][44][45][46], that the solution to the Inverse Heat Placement Problem does not usually consist of simple linear paths and significant scientific, engineering and mathematical challenges must be dealt with to make progress.…”

Section: Introductionmentioning

confidence: 99%

A rational approach to beam path planning in additive manufacturing: the inverse heat placement problem

et al. 2023

Self Cite

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High demand for components with complex geometries at macro and micro levels drives the development of additive manufacturing (AM). However, the scientific basis for designing energy beam scanning strategies (e.g. beam scanning speed, beam path, beam power) still relies on trial and error approaches (i.e. experimental/simulation of predefined beam trajectories) followed by the evaluation of process outcomes (e.g. structural/metallurgical properties of the built parts); this is the Direct Problem. To address such drawbacks, this paper reports, for the first time, a mathematical model for selecting key parameters related to beam exposure time in AM processes as an attempt to improve the build part's uniform properties, i.e. the Inverse Heat Placement Problem. Our algorithm yields variable beam scanning speeds and optimized beam paths for achieving a desired maximum temperature distribution (uniform or target pattern) and is suitable for different circumstances and scanning strategies dependent on the print part configuration. Here, raster and spiral predefined beam paths are chosen as examples. Variable beam scanning speeds and optimized beam paths obtained from our algorithm are able to induce a desirable uniform maximum temperature distribution compared with the conventional approach of constant beam scanning speeds and a predefined beam path.

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“…Axinte et al [ 35 ] demonstrated that, despite differences in their nature, many energy beam (EB) controlled-depth machining processes could be modelled using the same mathematical framework in the study of freeform surfaces machining. They have developed approaches and algorithms for the inverse problem to generate freeform surfaces using different EB machining processes and various workpiece target materials [ 36 ]. Wan et al [ 37 , 38 ] proposed a time-variant and space-variant tool influence function (TIF) model in the study of precision optical polishing.…”

Section: Introductionmentioning

confidence: 99%

An Investigation into Accumulative Difference Mechanism in Time and Space for Material Removal in Micro-EDM Milling

Zhang

et al. 2021

Micromachines

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In micro-electrical discharge machining (micro-EDM) milling, the cross-section of the microgroove machine is frequently not an ideal rectangle. For instance, there are arc shapes on the bottom and corners, and the sidewall is not steep. The theoretical explanation for this phenomenon is still lacking. In addition to the tip discharge effect, the essential reason is that there is an accumulative difference in time and space during the shape change process of a tool electrode and the microstructure formation on a workpiece. The process parameters are critical influencing factors that determine this accumulative difference. Therefore, the accumulative difference mechanism in time and space is investigated in this paper, and then a theoretical model is developed to simulate the micro-EDM milling process with a straight-line single path. The simulation results for a cylindrical electrode at the two rotational speeds of 0 (nonrotating) and 300 rpm are compared, while the results for a cylindrical electrode and a square electrode at a rotation speed of 0 are also compared to verify that different process parameters generate accumulative differences in the time and space of material removal. Finally, micro-EDM milling experiments are carried out to verify the simulation model. The maximum mean relative deviation between the microgroove profiles of simulation results and those of experiments is 11.09%, and the profile shapes of simulations and experiments have a good consistency. A comparative experiment between a cylindrical electrode and a hollow electrode is also performed, which further verifies the mechanism revealed in the study. Furthermore, the cross-section profile of a microgroove can be effectively controlled by adjusting the process parameters when utilising these accumulative differences through fabricating a microgroove with a V-shaped cross-section by a square electrode and a microgroove with a semi-circular cross-section by a cylindrical electrode. This research provides theoretical guidance for solving the problems of the machining accuracy of detail features in micro-EDM milling, for instance, to machine a microgroove with an ideal rectangular cross-section.

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Time-dependent manufacturing processes lead to a new class of inverse problems

Cited by 18 publications

References 10 publications

Post-processing of additively manufactured metallic alloys – A review

Post-processing of additively manufactured metallic alloys – A review

A rational approach to beam path planning in additive manufacturing: the inverse heat placement problem

An Investigation into Accumulative Difference Mechanism in Time and Space for Material Removal in Micro-EDM Milling

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