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Empirical Characterization of Track Dimensions for CMT-Based WAAM Processes

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Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems (FAIM 2023)

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

Abstract

Wire Arc Additive Manufacturing is based on a welding torch usually attached to a robotic arm with multiple degrees of freedom. Robot-based additive manufacturing allows non-planar and non-uniform thickness layers to be deposited where the slices have non-constant thickness. Thus, in addition to the motion settings, fine regulations of the welding parameters become necessary to obtain variable bead heights in the same slice. This paper aims to evaluate the user-accessible welding parameters’ influence on the deposited material’s dimensions during continuous Cold Metal Transfer (CMT) and its variant named CMT Cycle Step. In particular, the height and width of beads are investigated by varying the travel speed and the wire-feed rate (continuous CMT), as well as the size of the droplets by varying the number of CMT cycles and the wire-feed rate (CMT Cycle Step). In particular, the characterization of the material deposited during the CMT Cycle Step is not deeply studied in the literature. The experimental specimens are measured and the obtained values are numerically processed to yield empirical formulas that link the dimensions of the deposited material with the selected process parameters. The results show that CMT Cycle Step is more stable than continuous CMT, which confirms its higher suitability for accurate manufacturing.

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Acknowledgment

The authors wish to acknowledge the Guidetti Technology Srl (Modena, Italy) for their precious collaboration during the experimental work.

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Authors and Affiliations

  1. Department of Engineering “Enzo Ferrari”, University of Modena and Reggio Emilia, Modena, Italy

    Jacopo Lettori & Margherita Peruzzini

  2. Universidade Tecnológica Federal do Paraná, Campus Curitiba, Paraná, Brazil

    Jacopo Lettori & Milton Borsato

  3. Department of Sciences and Methods for Engineering, University of Modena and Reggio Emilia, Reggio Emilia, Italy

    Roberto Raffaeli, Pietro Bilancia & Marcello Pellicciari

Authors
  1. Jacopo Lettori
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  2. Roberto Raffaeli
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  3. Pietro Bilancia
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  4. Milton Borsato
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  5. Margherita Peruzzini
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  6. Marcello Pellicciari
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Corresponding author

Correspondence to Jacopo Lettori .

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Editors and Affiliations

  1. TEMA - Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Porto, Portugal

    Francisco J. G. Silva

  2. TEMA - Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal

    António B. Pereira

  3. Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal

    Raul D. S. G. Campilho

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© 2024 The Author(s), under exclusive license to Springer Nature Switzerland AG

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Lettori, J., Raffaeli, R., Bilancia, P., Borsato, M., Peruzzini, M., Pellicciari, M. (2024). Empirical Characterization of Track Dimensions for CMT-Based WAAM Processes. In: Silva, F.J.G., Pereira, A.B., Campilho, R.D.S.G. (eds) Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems. FAIM 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-38241-3_47

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  • DOI: https://doi.org/10.1007/978-3-031-38241-3_47

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  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-031-38240-6

  • Online ISBN: 978-3-031-38241-3

  • eBook Packages: EngineeringEngineering (R0)

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