Surface accuracy optimization of mechanical parts with multiple circular holes for additive manufacturing based on triangular fuzzy number

doi:10.1007/s11465-020-0610-6

Front. Mech. Eng.

2021, Vol. 16

Issue (1) : 133-150 https://doi.org/10.1007/s11465-020-0610-6

RESEARCH ARTICLE

Surface accuracy optimization of mechanical parts with multiple circular holes for additive manufacturing based on triangular fuzzy number

Jinghua XU¹, Hongsheng SHENG¹, Shuyou ZHANG¹(

), Jianrong TAN¹, Jinlian DENG²

¹. State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou 310027, China; Key Laboratory of Advanced Manufacturing Technology of Zhejiang Province, School of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China
². Zhejiang Institute of Mechanical and Electrical Engineering, Hangzhou 310053, China

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Abstract

Surface accuracy directly affects the surface quality and performance of mechanical parts. Circular hole, especially spatial non-planar hole set is the typical feature and working surface of mechanical parts. Compared with traditional machining methods, additive manufacturing (AM) technology can decrease the surface accuracy errors of circular holes during fabrication. However, an accuracy error may still exist on the surface of circular holes fabricated by AM due to the influence of staircase effect. This study proposes a surface accuracy optimization approach for mechanical parts with multiple circular holes for AM based on triangular fuzzy number (TFN). First, the feature lines on the manifold mesh are extracted using the dihedral angle method and normal tensor voting to detect the circular holes. Second, the optimal AM part build orientation is determined using the genetic algorithm to optimize the surface accuracy of the circular holes by minimizing the weighted volumetric error of the part. Third, the corresponding weights of the circular holes are calculated with the TFN analytic hierarchy process in accordance with the surface accuracy requirements. Lastly, an improved adaptive slicing algorithm is utilized to reduce the entire build time while maintaining the forming surface accuracy of the circular holes using digital twins via virtual printing. The effectiveness of the proposed approach is experimentally validated using two mechanical models.

Keywords surface accuracy optimization multiple circular holes additive manufacturing (AM) part build orientation triangular fuzzy number (TFN) digital twins

Corresponding Author(s): Shuyou ZHANG

Just Accepted Date: 31 December 2020 Online First Date: 07 February 2021 Issue Date: 11 March 2021

Cite this article:

Jinghua XU,Hongsheng SHENG,Shuyou ZHANG, et al. Surface accuracy optimization of mechanical parts with multiple circular holes for additive manufacturing based on triangular fuzzy number[J]. Front. Mech. Eng., 2021, 16(1): 133-150.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-020-0610-6
https://academic.hep.com.cn/fme/EN/Y2021/V16/I1/133

Fig.1 One-ring neighbor triangular facets of vertex v in the manifold mesh.

Fig.2 Eigenvalues of normal tensor voting for corresponding features.

Fig.3 Circular hole features on a plane and curved surface. (a) Feature lines of the STL model; (b) triangular facet sets of circular holes.

Fig.4 Staircase effect in the additive manufacturing fabrication process.

Fig.5 Staircase effect in one triangular facet.

Tab.1 Standard values of RI

Fig.6 Overlapping area of two non-planar circular holes along the build direction.

Fig.7 (a) Original trestle manifold model with spatial non-planar hole set; (b) trestle surface accuracy requirements on six holes; (c) original gearbox manifold model; (d) gearbox surface accuracy requirements on four holes. Ra: Surface roughness.

Fig.8 (a) Circular closed line loops of the trestle; (b) triangular facet sets of the circular holes of the trestle; (c) circular closed line loops of the gearbox; (d) triangular facet sets of the circular holes of the gearbox.

Tab.2 Circular hole information of the trestle

Tab.3 Circular hole information of the gearbox

Fig.9 WVE objective function landscapes: (a) Trestle and (b) gearbox.

Fig.10 Slicing results at the original and optimal build orientation of the trestle. (a) Uniform slicing at the original orientation; (b) uniform slicing at the original orientation on XZ plane; (c) uniform slicing at the optimal orientation; (d) uniform slicing at the optimal orientation on XZ plane; (e) adaptive slicing at the optimal orientation; (f) adaptive slicing at the optimal orientation on XZ plane.

Fig.11 Cusp heights of the trestle. (a) Three slicing results; (b) six circular holes with adaptive slicing at the optimal orientation.

Fig.12 Slicing results at the original and optimal build orientation of the gearbox. (a) Uniform slicing at the original orientation; (b) uniform slicing at the original orientation on XZ plane; (c) uniform slicing at the optimal orientation; (d) uniform slicing at the optimal orientation on XZ plane; (e) adaptive slicing at the optimal orientation; (f) adaptive slicing at the optimal orientation on XZ plane.

Fig.13 Cusp heights of the gearbox. (a) Three slicing results; (b) four circular holes with adaptive slicing at the optimal orientation.

Fig.14 Visualized virtual printing of FDM printing for the trestle. (a) Uniform slicing at the original orientation; (b) uniform slicing at the optimal orientation; (c) adaptive slicing at the optimal orientation.

Fig.15 Visualized virtual printing of FDM printing for the gearbox. (a) Uniform slicing at the original orientation; (b) uniform slicing at the optimal orientation (90°, 0°); (c) uniform slicing at the optimal orientation (90°, 180°); (d) adaptive slicing at the optimal orientation.

Fig.16 Fabricated trestle models after stripping the supports for (a) Fig. 14(a), (b) Fig. 14(b), and (c) Fig. 14(c).

Fig.17 Fabricated gearbox castings after stripping the external supports for (a) Fig. 15(a), (b) Fig. 15(b), (c) Fig. 15(c), and (d) Fig. 15(d).

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