About this Abstract |
Meeting |
2025 TMS Annual Meeting & Exhibition
|
Symposium
|
Additive Manufacturing Modeling, Simulation and Machine Learning
|
Presentation Title |
Preventing Substrate Distortion Using Hybrid Additive and Subtractive Approach |
Author(s) |
Wen Dong, Blane Fillingim, Bhagya Prabhune, Lauren Heinrich, Thomas Feldhausen, Srdjan Simunovic, Yousub Lee |
On-Site Speaker (Planned) |
Wen Dong |
Abstract Scope |
In metal additive manufacturing such as directed energy deposition, warping of substrate changes heat conduction path resulting in degradation of part properties. Also, larger substrate distortion can lead to clamp failure and even severe table bending, potentially causing stoppage of entire manufacturing process. While distortion can be prevented using a proper clamping system, the substrate may deform during and after the clamps are released. This work introduces a novel hybrid additive and subtractive manufacturing approach to minimize plate distortion by adopting a real-time optimization method that engraves cut-patterns on the substrate. The optimal patterns on the substrate are computed by combining finite element-based process modeling with topology optimization. During deposition, the hybrid system can repeatedly machine the substrate creating optimal cut-pattens for minimal plate distortion. The effectiveness of this method will be demonstrated through both numerical simulations and experimental validations. |
Proceedings Inclusion? |
Planned: |
Keywords |
Additive Manufacturing, Modeling and Simulation, |