Simulation and control of metal droplet transfer in bypass coupling wire arc additive manufacturing

The influences of bypass current and wire feed speed are utilized to change the metal droplet transfer mode for bypass coupling wire-arcing additive manufacturing (BC-WAAW). To fully understand the influence of experimental factors on the wire melting process, this study establishes a mathematical m...

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Bibliographic Details
Published inInternational journal of advanced manufacturing technology Vol. 115; no. 1-2; pp. 383 - 395
Main Authors Huang, Jiankang, Guan, Zhichen, Yu, Shurong, Yu, Xiaoquan, Yuan, Wen, Liu, Shien, Fan, Ding
Format Journal Article
LanguageEnglish
Published London Springer London 01.07.2021
Springer Nature B.V
Subjects
Additive manufacturing
CAE) and Design
Computer-Aided Engineering (CAD
Control methods
Control stability
Control systems
Coupling
Deposition
Droplets
Engineering
Feedback control
Fillers
Industrial and Production Engineering
Influence
Mathematical analysis
Mathematical models
Mechanical Engineering
Media Management
Melting
Multilayers
Negative feedback
Original Article
Simulation
Wire
Negative feedback control
Bypass coupling
Simulation and control
Additive manufacturing
Wire melting process
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Summary:The influences of bypass current and wire feed speed are utilized to change the metal droplet transfer mode for bypass coupling wire-arcing additive manufacturing (BC-WAAW). To fully understand the influence of experimental factors on the wire melting process, this study establishes a mathematical model for the wire melting process, and several simulation experiments are carried out to prove the effectiveness of this mathematical model. The influence of changing the filler wire process on the stability of the wire melting process is simulated. A negative feedback control method with a single input and single output is proposed, which can control the stability of the wire melting process. The results show that the established mathematical model can well reflect the wire melting process in bypass coupling arcing additive manufacturing. The wire feed speed has a strong influence on the wire extension. The negative feedback control method can realize real-time control of filler wire process stability. The deposition process is more stable in the arcing additive manufacturing process, and the forming accuracy of a single multilayer deposition wall is further improved.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-021-07212-1