Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Three-Dimensional geometry profile extraction of deposits using linear laser scanning in the directed energy deposition additive manufacturing method

Document Type : Original Article

Authors
Sara Esfandiari Ghollezu 1
Mohammad Hossein Farshidianfar 2
Sina Nejati Eghteda 3
1 MSc Student, Department of Mechanical Engineering, Ferdowsi University of Mashhad, Mashhad, Iran
2 Assistant Professor, Department of Mechanical Engineering, Ferdowsi University of Mashhad, Mashhad, Iran
3 PhD Student, Department of Mechanical Engineering, University of Pittsburgh, Pittsburgh, United States
10.22034/ijme.2024.435811.1919
Abstract
This research is focused on the examination of laser and its application in additive manufacturing. Additive manufacturing is a process in which a three-dimensional model is manufactured layer by layer and from the bottom up. Advances in this powerful and promising process have resulted in a rise in the demand for its applications in the industry. However, controlling the geometry of the deposited material throughout the additive manufacturing process remains a significant challenge. Geometric control and correspondence with the target geometry are key subjects in the additive manufacturing process. This research aims to obtain geometric data of the three-dimensional profile in deposition using the Direct Energy Deposition (DED) method. By imaging the interface of a laser line and the surface of the coating and extracting the resulting line using image processing methods, the profile of one section of the coating is obtained. By applying the same steps to all of the coating's sections and stacking the images, a three-dimensional profile of the coating's profile is constructed. By checking the correspondence between the proposed algorithm's output image and a microscopic image of the same section, the accuracy of this method is assessed. The result of the comparison between these two images indicates an error of 0.29 mm in width and -0.07 mm in height, falling within the range of error defined by ISO guidelines.
Keywords
Additive Manufacturing
Directed Energy Deposition
Deposition Geometry Control
Image Processing
Laser Line Scanning

Subjects

[1] Kaji F, Nguyen-Huu H, Budhwani A, Narayanan JA, Zimny M, Toyserkani E. A deep-learning-based in-situ surface anomaly detection methodology for laser directed energy deposition via powder feeding. Journal of Manufacturing Processes. 2022;81:624-37. doi: 10.1016/j.jmapro.2022.06.046
[2] Hooshmand M. J, Mansour S. Investigating the effect of build orientation on surface roughness and build time using Fused Deposition Modelling. Iranian Journal of Manufacturing Engineering. 2021;7(12):37- 53. [In Persian]
[3] Binega E, Yang L, Sohn H, Cheng JC. Online geometry monitoring during directed energy deposition additive manufacturing using laser line scanning. Precision Engineering. 2022;73:104-14. doi: 10.1016/j.precisioneng.2021.09.005
[4] Heralić A, Christiansson A-K, Ottosson M, Lennartson B. Increased stability in laser metal wire deposition through feedback from optical measurements. Optics and Lasers in Engineering. 2010;48(4):478-85. doi: 10.1016/j.optlaseng.2009.08.012
[5] Li Z, Liu X, Wen S, He P, Zhong K, Wei Q, et al. In situ 3D monitoring of geometric signatures in the powder-bed-fusion additive manufacturing process via vision sensing methods. Sensors. 2018;18(4):1180. doi: 10.3390/s18041180
[6] Faes M, Abbeloos W, Vogeler F, Valkenaers H, Coppens K, Goedemé T, Ferraris E. Process monitoring of extrusion based 3D printing via laser scanning. arXiv preprint arXiv:161202219. 2016. doi: 10.13140/2.1.5175.0081
[7] Borish M, Post BK, Roschli A, Chesser PC, Love LJ, Gaul KT. Defect identification and mitigation via visual inspection in large-scale additive manufacturing. Jom. 2019;71:893-9. doi: 10.1007/s11837-018-3220-6
[8] Lin W, Shen H, Fu J, Wu S. Online quality monitoring in material extrusion additive manufacturing processes based on laser scanning technology. Precision Engineering. 2019;60:76-84. doi: 10.1016/j.precisioneng.2019.06.004
[9] Khalili Kh, Emam S. M. Dimensional control of sand particles based on the Iranian National Standard Organization using image processing technique. Iranian Journal of Manufacturing Engineering. 2018;5(3):52-62. [In Persian]
[10] Craig JJ. Introduction to robotics: Pearson Educacion; 2006.
[11] Mittone A, Manakov I, Broche L, Jarnias C, Coan P, Bravin A. Characterization of a sCMOS-based high-resolution imaging system. Journal of synchrotron radiation. 2017;24(6):1226-36. doi: 10.1107/s160057751701222x
[12] Zhou C, Nayar SK. Computational cameras: convergence of optics and processing. IEEE Transactions on Image Processing. 2011;20(12):3322-40. doi: 10.1109/TIP.2011.2171700
 
Iranian Journal of Manufacturing Engineering
Volume 10, Issue 7 - Serial Number 69
September 2023
Pages 17-25