Variable Powder Flow Rate Control in Laser Metal Deposition Processes

This paper proposes a novel technique, called Variable Powder Flow Rate Control (VPFRC), for the regulation of powder flow rate in laser metal deposition processes. The idea of VPFRC is to adjust the powder flow rate to maintain a uniform powder deposition per unit length even when disturbances occur (e.g., the motion system accelerates and decelerates). Dynamic models of the powder delivery system motor and the powder transport system (i.e., five–meter pipe, powder dispenser, and cladding head) are first constructed. A general tracking controller is then designed to track variable powder flow rate references. Since the powder flow rate at the nozzle exit cannot be directly measured, it is estimated using the powder transport system model. The input to this model is the DC motor rotation speed, which is estimated on–line using a Kalman filter. Experiments are conducted to examine the performance of the proposed control methodology. The experimental results demonstrate that VPFRC is successful in maintaining a uniform track morphology, even when the motion control system accelerates and decelerates.Mechanical Engineerin

Process Control of Laser Metal Deposition Manufacturing -- A Simulation Study

The laser metal deposition process is a rapid manufacturing operation capable of producing functional prototypes with complex geometries and thin sections. This process inherently contains significant uncertainties and, therefore, extensive experimentation must be performed to determine suitable process parameters. An alternative is to directly control the process on-line using feedback control methodologies. In this paper, a nonlinear control strategy based on feedback linearization is created to automatically regulate the bead morphology and melt pool temperature. Extensive simulation studies are conducted to validate the control strategy

Regulation of Powder Mass Flow Rate in Gravity-Fed Powder Feeder Systems

Precise regulation of powder mass flow in laser-based manufacturing processes is critical to achieving excellent part dimensional and microstructure quality. Control of powder mass flow is challenging because low flow rates, where nonlinear effects are significant, are typically required. Also, gravity-fed powder feeder systems have significant material transport delays, making the control of powder mass flow even more challenging. This paper presents a control strategy for regulating the powder mass flow rate in a gravity-fed powder feeder system. A dynamic model of the powder feeder system, including material transport delay, is constructed, and a modified proportional plus integral (PI) controller is designed. An observer is used to estimate powder mass flow rate using the powder feeder motor encoder signal. The control strategy is implemented in a Smith Predictor Corrector Structure, which has been adjusted such that it can be applied to the modified PI controller, to account for the inherent material transport delay. Experimental studies are conducted that validate the dynamic model and controller strategy

Output Feedback Force Control for a Parallel Turning Operation

Parallel machine tools (i.e., machine tools capable of cutting a part with multiple tools simultaneously but independently) are being utilized more and more to increase operation productivity, decrease setups, and reduce floor space. Process control is the utilization of real-time process sensor information to automatically adjust process parameters (e.g., feed, spindle speed) to increase operation productivity and quality. To date, however, these two technologies have not been combined. This paper describes the design of an output feedback controller for a parallel turning operation that accounts for the inherent nonlinearities in the force process. An analysis of the process equilibriums explains the system stability behavior for different design specifications and the reverse trajectory method is used to numerically determine the exact stability boundary. Effects of saturation on stability are also analyzed and from this sufficient conditions for global stability are obtained

Modular Control Laboratory System with Integrated Simulation, Animation, Emulation, and Experimental Components

A typical sequence for the design of a controller, given the desired objectives, is the following: system modeling, design and mathematical analysis, simulation studies, emulation, and experimental implementation. Most control courses thoroughly cover design and mathematical analysis and utilize a simulation or experimental project at the end of the course. However, animation and emulation are seldom utilized and projects rarely cover the entire controller design sequence. This paper presents a control laboratory system developed at the University of Missouri at Rolla that integrates simulation, animation, emulation, and experimental components. The laboratory system may be applied to a wide variety of controls courses, from undergraduate to graduate. In addition to the simulation and experimental studies, students utilize animation and emulation components. Animation allows the students to visualize, as well as validate, their controllers during the simulation design phase, and emulation allows students to debug their programs on the target processor before experimentally implementing their controllers. Two experiments are presented to demonstrate the modular control laboratory system

Freeform Extrusion of High Solids Loading Ceramic Slurries, Part I: Extrusion Process Modeling

A novel solid freeform fabrication method has been developed for the manufacture of ceramic-based components in an environmentally friendly fashion. The method is based on the extrusion of ceramic slurries using water as the binding media. Aluminum oxide (Al2O3) is currently being used as the part material and solids loading as high as 60 vol. % has been achieved. This paper describes a manufacturing machine that has been developed for the extrusion of high solids loading ceramic slurries. A critical component of the machine is the deposition system, which consists of a syringe, a plunger, a ram actuated by a motor that forces the plunger down to extrude material, and a load cell to measure the extrusion force. An empirical, dynamic model of the ceramic extrusion process, where the input is the commanded ram velocity and the output is the extrusion force, is developed. Several experiments are conducted and empirical modeling techniques are utilized to construct the dynamic model. The results demonstrate that the ceramic extrusion process has a very slow dynamic response, as compared to other non-compressible fluids such as water. A substantial amount of variation exists in the ceramic extrusion process, most notably in the transient dynamics, and a constant ram velocity may either produce a relatively constant steady-state extrusion force or it may cause the extrusion force to steadily increase until the ram motor skips. The ceramic extrusion process is also subjected to significant disturbances such as air bubble release, which causes a dramatic decrease in the extrusion force, and nozzle clogging, which causes the extrusion force to slowly increase until the clog is released or the ram motor skips.Mechanical Engineerin

Freeform Extrusion of High Solids Loading Ceramic Slurries, Part II: Extrusion Process Control

Part I of this paper provided a detailed description of a novel fabrication machine for high solids loading ceramic slurry extrusion and presented an empirical model of the ceramic extrusion process, with ram velocity as the input and extrusion force as the output. A constant force is desirable in freeform extrusion processes as it correlates with a constant material deposition rate and, thus, good part quality. The experimental results in Part I demonstrated that a constant ram velocity will produce a transient extrusion force. In some instances the extrusion force increased until ram motor skipping occurred. Further, process disturbances, such as air bubble release and nozzle clogging that cause sudden changes in extrusion force, were often present. In this paper a feedback controller for the ceramic extrusion process is designed and experimentally implemented. The controller intelligently adjusts the ram motor velocity to maintain a constant extrusion force. Since there is tremendous variability in the extrusion process characteristics, an on-off controller is utilized in this paper. Comparisons are made between parts fabricated with and without the feedback control. It is demonstrated that the use of the feedback control reduces the effect of process disturbances (i.e., air bubble release and nozzle clogging) and dramatically improves part quality.Mechanical Engineerin

Stability Analysis of Nonlinear Machining Force Controllers

Model parameters vary significantly during a normal operation, thus, adaptive techniques have predominately been used. However, model-based techniques that carefully account for changes in the force process have again been examined due to the reduced complexity afforded by such techniques. In this paper, the effect of model parameter variations on the closed-loop stability for two model-based force controllers is examined. It was found that the stability boundary in the process parameter space can be exactly determined for force control systems designed for static force processes. For force control systems designed for first-order force processes, it was found that the stability boundary is sensitive to the estimate of the discrete-time pole. The analysis was verified via simulations and experimental studie