Forming Control via Interval Width in Directed Energy Deposition-Arc Process

Author:

Wang Qingyuan12,Wang Zhen12,Xie Yuhang12,Huang Jiankang12ORCID,Yu Xiaoquan3,Yu Shurong4,Fan Ding12ORCID

Affiliation:

1. State Key Laboratory of Advanced Processing and Recycling of Non-Ferrous Metal, Lanzhou University of Technology, Lanzhou 730050, China

2. School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou 730050, China

3. Taizhou Institute of Zhejiang University, Zhejiang University, Taizhou 318000, China

4. School of Mechanical and Electrical Engineering, Lanzhou University of Technology, Lanzhou 730050, China

Abstract

A novel controller, employing a variable-structure single-neuron adaptive PSD (proportional integral derivative) approach, was proposed for regulating the deposition width variation in the Directed Energy Deposition-Arc (DED-Arc) layer. During experimental trials, the deposition speed was chosen as the manipulated variable, while the width of the deposition layer served as the measured parameter. To facilitate controller design, a vision sensor was custom-designed to accurately detect the width of the deposition layer. The captured image of the deposition layer’s dimensions enabled the precise determination of the deposited thickness, forming the basis for subsequent controller development. In performance assessments, deliberate interference was intentionally introduced into the deposition current, deposition layer height, and the targeted deposition layer width. The assessment involved the controlled deposition of ten-layer components, focusing on width regulation for each deposition layer. The results demonstrate that the proposed controller significantly enhances the deposition process stability, particularly within a range of desired deposition widths from 7.5 mm to 8.3 mm.

Funder

National Natural Science Foundation of China

Major Science and Technology Project of the Gansu Province

Publisher

MDPI AG

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