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Interests of 5 axis toolpaths generation for Wire Arc Additive Manufacturing of aluminum alloys

Hascoët J.-Y., Querard V., Rauch M.

Journal of Machine Engineering

2017

Vol. 17, No. 3

51--65

Additive Manufacturing (AM) for metal part can be divided into two different types: The powder technology and the wire technology. Usually, powder is adapted for fine components and small parts whereas wire is used for structural components and large scale part. One of the main benefits of AM is to simplify assemblies by reducing the number of components and to provide a large freedom of design. A standard AM system consists of a combination of three blocks: a motion system, a heat source and a feedstock. For Wire Arc Additive Manufacturing (WAAM), the heat source is a welding generator and the feedstock is a wire. The motion system generally used is a 6 axis robot or a CNC machine. This paper aims to propose a methodology to generate 5 axis toolpaths for WAAM and highlight the main parameters which selection is a key issue to resolve. The goal is to compare 3 axis and 5 axis toolpaths on part accuracy, depending the clearance angle of the part.

A new strategy of tool path planning based on hydrodynamic data to machine marine propeller

Breteau T., Damay T., Duc E., Hascoët J.-Y.

Journal of Machine Engineering

2009

Vol. 9, No. 1

29--40

Marine propellers are complex surfaces that are usually machined with a perfect roughness in order not to disturb the theoretical flow. Because this requirement is penalizing from a manufacturing point of view, the global objective of the study is to propose an approach in which the machining parameters are linked to functional properties of the blade in order to remove the polishing phase. To reach this objective, hydrodynamic data are used: streak lines, that are computed during the propeller design phase, characterize the fluid behavior at the close vicinity of the blade. Those lines, which are theoretically continuous at the leading edge, turn out to be discontinuous, due to the computing method. To be consistent with the fluid behavior as much as possible, the idea presented in the paper is to compose a continuous trajectory, especially at the leading edge, to mill the surface. Thus, an algorithm is developed to plan tool paths which are smoothed at leading edge using Bezier curves. Moreover, this algorithm allows to quantify the cusp height at the leading edge to avoid a drop in performance using criteria linked to the dynamical behavior of a five axis machine tool. In this work, a strategy is developed and enables multiaxial milling of a blade surface by using geometric and hydrodynamic data and by respecting the associated constraints.