Complex interaction between CMT equipment and robot controllers during the WAAM process: consequences for toolpath accuracy

• DOI: 10.1007/s00170-023-11928-7
• Publication Date: 2023-07-18T08:02:23Z
• Authors: Ricardo Da Silva ...; Xavier Balandraud; Fabien Poulhaon; Pierre Michaud; Emmanuel Duc
• Keywords: Realization (probability); Deposition

Abstract In the WAAM process, the accuracy of the toolpath is of prime importance for the mechanical properties of the final part because of the material defects that could be generated. This paper deals with the motion analysis of the end effector nozzle of a robot dedicated to the WAAM process. The movement of the nozzle to create a rectangular layer was experimentally analyzed without physically depositing material (trajectory definition only). Various strategies, nozzle speeds and layer areas were compared in terms of travel time and length over different sections of the toolpath in order to identify various problems, in particular associated with acceleration and deceleration phases when changing direction. The consequences of a discontinuous deposition were also studied, revealing a complex interaction between cold metal transfer equipment and robot controllers. The results enable a better understanding of this interaction, which is important for deposition quality and performance. Finally, a model was proposed to calculate the manufacturing time of any layer area based on a preliminary identification for a single area.