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Suggesting a new CNC framework for wire and arc additive manufacturing

Wire and arc additive manufacturing (WAAM) has attracted more and more research interest nowadays. In WAAM, the travel speed should keep as high as possible for a high deposition rate, and as constant as possible for a uniform deposition morphology along the tool-path. Nevertheless, the two goals are always violated in practice because the welding robot, controlled by CNC (Computer Numerical Control), has to slow down when sharp corners with high curvatures are encountered so as to respect the dynamic constraint. To cope with this problem, a new CNC framework is proposed with the objective of guaranteeing a uniform deposition morphology along the tool-path while still respecting the dynamic constraint. The idea is to split the tool-path into several segments depending on whether they contain sharp corners and then determine the allowable travel speed of each segment separately subjected to the dynamic constraint. In addition, the wire-feed rate is adaptively controlled to match the corresponding travel speed for a uniform deposition morphology. Experimental results demonstrate that the new CNC framework greatly improves the uniformity of the deposition morphology compared to the conventional one.