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Model-Based Feedforward Control of Part Height in Directed Energy Deposition

机译：基于模型的馈电控制零件高度的馈电控制

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摘要

Control of the geometric accuracy of a metal deposit is critical in the repair and fabrication of complex components through Directed Energy Deposition (DED). This paper developed and experimentally evaluated a model-based feedforward control of laser power with the objective of achieving the targeted part height in DED. Specifically, based on the dynamic model of melt-pool geometry derived from our prior work, a nonlinear inverse-dynamics controller was derived in a hatch-by-hatch, layer-by-layer manner to modulate the laser power such that the melt-pool height was regulated during the simulated build process. Then, the laser power trajectory from the simulated closed-loop control under the nonlinear inverse-dynamics controller was implemented as a feedforward control in an Optomec Laser-Engineered Net Shape (LENS) MR-7 system. This paper considered the deposition of L-shaped structures of Ti-6AL-4V as a case study to illustrate the proposed model-based controller. Experimental validation showed that by applying the proposed model-based feed-forward control for laser power, the resulting build had 24–42% reduction in the average build height error with respect to the target build height compared to applying a constant laser power through the entire build or applying a hatch-dependent laser power strategy, for which the laser power values were obtained from experimental trial and error.
机译：通过定向能量沉积（DED）对金属沉积物的几何精度的控制对于复杂组分的修复和制造至关重要。本文开发并通过实验评估了基于模型的激光功率的前馈控制，其目的是实现了DED中的目标部分高度。具体地，基于熔融池几何形状的动态模型从我们的先前工作得出，非线性逆动力控制器在逐个舱口，逐层方式中导出，以调制激光功率，使得熔体 - 池高度在模拟构建过程中受到调节。然后，从非线性逆动力控制器下的模拟闭环控制下的激光功率轨迹被实现为Optomec激光工程净形状（镜头）MR-7系统中的前馈控制。本文认为，Ti-6AL-4V的L形结构的沉积作为案例研究，以说明所提出的基于模型的控制器。实验验证表明，通过对激光功率应用所提出的基于模型的前馈控制，与施加恒定激光功率相比，通过恒定激光功率相比，所得到的构建相对于目标构建高度的平均构建高度误差24-42％。整个构建或应用舱口依赖性激光功率策略，激光功率值是从实验试验和误差获得的。

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