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Optimizing the mean and variance of bead geometry in the wire + arc additive manufacturing using a desirability function method

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Abstract

Wire + arc additive manufacturing is an arc welding process that uses non-consumable tungsten electrodes to produce the weld. The material used in this study is a titanium, carbon, zirconium, and molybdenum alloy that is physically and chemically stable and has good performance for use as a welding and high-temperature heating element. In this study, welding experiments are designed based on a central composite design, and single-layer wire + arc additive manufacturing is performed using the titanium, carbon, zirconium, and molybdenum alloy. Consequently, 17 beads are obtained and the height, width, left and right toe angles, which represent the geometry of the beads are measured. Based on the measured geometry, response surface models for mean and standard deviation of the four geometries are fitted. Mean absolute percentage error of the four response surface models is 16.6% on average which implies that the models are reasonably well fitted. Based on the response surface models, the optimal settings for the Wire + arc additive manufacturing parameters are obtained by using a desirability function method. At the optimal setting, the desirability function value shows 0.85 on average which is close to ideal value of 1.00. This result indicates that valid optimal settings for the process parameters can be obtained via the proposed method.

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Funding

This research was supported by the MSIT (Ministry of Science, ICT), Korea, under the High-Potential Individuals Global Training Program) (No. 2020–0-01539) supervised by the IITP (Institute for Information & Communications Technology Planning & Evaluation).

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Authors and Affiliations

  1. Division of Interdisciplinary Industrial Studies, Hanyang University, 222 Wangsimni-ro, Seongdong-gu, Seoul, 04763, Republic of Korea

    Jin-Soo Cho & Seung-Jun Shin

  2. Department of Industrial Engineering, Sungkyunkwan University, 2066 Seobu-ro, Jangan-gu, Suwon, 16419, Republic of Korea

    Dong-Hee Lee

  3. Department of Manufacturing and Engineering Technology, Tennessee Technological University, 1 William L Jones Drive, Cookeville, TN, 38505, USA

    Gi-Jeong Seo & Duck-Bong Kim

Authors
  1. Jin-Soo Cho
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  2. Dong-Hee Lee
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  3. Gi-Jeong Seo
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  4. Duck-Bong Kim
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  5. Seung-Jun Shin
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Correspondence to Dong-Hee Lee.

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Highlights

• Massive measurement data for the TZM bead geometry were collected using a coordinate measuring machine.

• The mean and variance of the TZM bead geometry were modeled as second-order models using response surface methodologies.

• The optimal settings for the wire + arc additive manufacturing process parameters were obtained via a desirability function method.

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Cho, JS., Lee, DH., Seo, GJ. et al. Optimizing the mean and variance of bead geometry in the wire + arc additive manufacturing using a desirability function method. Int J Adv Manuf Technol 120, 7771–7783 (2022). https://doi.org/10.1007/s00170-022-09237-6

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  • DOI: https://doi.org/10.1007/s00170-022-09237-6

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