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.