Generation of functional surfaces to assist in decision-making for wire arc additive manufacturing

Traditionally, product development involved separate design and manufacturing processes, leading to significant challenges in cost, time, and quality. However, the advent of Computer-aided design (CAD) systems in the late 20th century bridged this gap, enabling a seamless exchange of design information and coinciding with the rise of Additive Manufacturing (AM) processes. A critical aspect of CAD/CAM systems is determining the functional specification of CAD assembly models, with design tolerances directly impacting product buildability. However, accessing this data remains complex. This paper presents an approach to extract feature surfaces from assembly models automatically. Initially, assembly constraints are analyzed to determine component relationships, which are then used to extract corresponding functional surfaces. This algorithmic process includes two pivotal phases: one for surface characterization and another for exploring constraints. This approach yields a comprehensive representation of functional surfaces associated with the components. Addressing this challenge, the effectiveness of this approach is demonstrated through an illustrative example, showcasing the extraction of information related to functional surfaces from the outset of the process. After conducting a thorough comparative analysis, specifically targeting the mechanical properties of parts produced using Cold Metal Transfer (CMT) and Cold Metal Transfer Cycle Step techniques, it was determined tS100hat CMT is best suited for constructing the main body of the component. Meanwhile, the CMT Cycle Step will be used for producing surrounding volumes. This strategic allocation ensures that each technique is employed to maximize its strengths, optimizing performance and efficiency throughout the manufacturing process. In conclusion, a hybrid approach combining both CMT and CMT Cycle Step techniques, while considering functional surfaces. This integrated strategy capitalizes on the strengths of each method.