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A Motion State-based Printing Time Modeling and Printing Cost Analysis for Laser Direct Deposition Process

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Abstract

Laser direct deposition (LDD) process is widely used in the manufacture of complex parts with the advantages of high-precision and high-performance, while it is facing the problems of low efficiency, high-energy consumption, and high cost. During LDD, printing time not only affects efficiency, energy, and cost but also is constrained by factors of parts—volume, process parameters, and deposition modes. Printing time modeling is quite difficult when taking cladding head motion and deposition path into consideration. In this research, the discontinuous and non-uniform motion state of cladding head was obtained by analyzing the variation of laser power, and the discontinuous deposition path was further acquired by discussing the occurrence of light powder coupling. Therefore, a motion state-based printing time model was proposed to quantify sub-time during deposition process. Subsequently, a printing time-driven printing cost model was established to reveal the correlation of efficiency, energy, and cost under different deposition modes. Orthogonal experiment and comparative experiment were carried out. Results showed that the printing time model accuracy exceeds 90%. The comparative results of different deposition modes suggested that printing time is positively related to the continuity length of deposition path, thus leading to significant differences in energy consumption and printing cost. According to the structure and sensitivity analysis of printing cost, machine and powder cost account for 40 and 36%, respectively, and machine purchase price and powder price are the most sensitive factors. This research provides a novel methodology for measuring printing time and offers a comparative assessment of deposition modes for sustainable manufacturing.

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Abbreviations

LDD:

Laser direct deposition

r valid :

Path where light powder coupling occurs [mm]

r idle :

Path where no light powder coupling occurs [mm]

n :

The number of nodes [nodes]

t build :

Printing time of laser direct deposition parts [s]

t eff :

The time required for the cladding head to move valid deposited path [s]

t ex :

The time required for the laser machine to complete the transition state of turning on or off laser beam at a node

e total :

Total energy consumption of laser direct deposition process [KJ]

FDP:

Feature deposited parts

C build :

Total cost of the deposition process [RNB]

C material :

Material cost of laser direct deposition process [RNB]

C machine :

Machine cost of laser direct deposition process [RNB]

C gas :

Gas cost of laser direct deposition process [RNB]

E total :

Total energy consumption of laser direct deposition process [kw/h]

SEC :

Electric energy consumption per unit volume of deposited parts [KJ/cm3]

V part :

The volume of the formed parts [cm3]

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Funding

This research was supported by the Natural Science Foundation of Hunan Province, China (Grant No. 2020JJ4202) and the National Natural Science Foundation of China (Grant No. 51605156). Their financial contributions are gratefully acknowledged.

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Authors and Affiliations

  1. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha, 410082, People’s Republic of China

    Haiying Wei, Keke Deng, Yuan Tan & Wen Liu

  2. Key Laboratory for Intelligent Laser Manufacturing of Hunan Province, Hunan University, Changsha, 410082, People’s Republic of China

    Haiying Wei, Keke Deng, Yuan Tan & Wen Liu

Authors
  1. Haiying Wei
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Contributions

Haiying Wei: conceptualization, methodology, data analysis, supervision, writing-review and editing. Keke Deng: experiment, methodology, modeling, data analysis, validation, original draft writing. Yuan Tan: experiment, methodology, data analysis. Wen Liu: experiment, data analysis.

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Correspondence to Haiying Wei.

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Wei, H., Deng, K., Tan, Y. et al. A Motion State-based Printing Time Modeling and Printing Cost Analysis for Laser Direct Deposition Process. Int J Adv Manuf Technol 114, 3109–3121 (2021). https://doi.org/10.1007/s00170-021-07064-9

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