Simulation-based design of laser-based free forming process control

Conventional machining processes create high value products with high production cost that is often a result of long processing time and excessive waste materials. A laser-based, free-forming process, on the other hand, permits the manufacture of products with little to no waste by direct depositing material layer-by-layer onto the part. As a result, production costs are significantly reduced. However, because these parts are created layer-by-layer, their quality must be closely controlled during the process to avoid the costs incurred in producing defective products. Furthermore, incomplete products will be rejected when the process is terminated. A process controller, therefore, is necessary to perform this process with little or no defects. This article presents a simulation-based design of a laser-based. free-forming process controller. The relationships are defined between process characteristics and three process parameters: laser power, translation speed, and powder flow rate. These relationships are then used to design the process controller. Simulation results from each step are also presented. (C) 2001 Laser Institute of America.