Doctoral Dissertations

Keywords and Phrases

Control-oriented model; iterative learning control; powder bed fusion; state-space control model

Abstract

"Powder Bed Fusion (PBF) is an Additive Manufacturing (AM) technique which can reduce material waste and is a fast-prototyping technique for complex geometries. However, the lack of consistent quality is a major problem in industrial applications. An InfraRed (IR) camera is a common tool to monitor a surface temperature field and melt pool morphology in PBF. With melt pool features from camera videos, manufacturing researchers use spatial feature maps to visualize defect locations and control researchers use layer-to-layer control to achieve more uniform melt pools and less defects.

Paper I presents a simulation method to characterize the effect of down-sampling on melt pool thermal feature measurements. Based on high-fidelity simulation data, the characterization reveals the complexity of the spatial down-sampling effect and provides a reference of signal quality for different thermal features under low resolutions.

Paper II presents a novel spatial, layer-to-layer, state-space control-oriented model for PBF, which transforms a temporal heat transfer model into a voxel-based spatial model, which is easy to analyze and implement. Output controllability is discussed. Simulations are presented to demonstrate the framework of spatial layer-to-layer control.

Paper III proposes a controller suitable for a layer-variant PBF system. The PBF system dynamic model is needed for control implementation but difficult to determine analytically. A MultiLayer Perceptron (MLP) network is used to classify thermal dynamics of different geometries and estimate them. With the MLP, a modified Iterative Learning Control (ILC) method is presented and analyzed, which has a better performance than a regular ILC"-- Abstract, p. iv

Advisor(s)

Bristow, Douglas A.

Committee Member(s)

Landers, Robert G.
Leu, M. C. (Ming Chuan)
Sarangapani, Jagannathan, 1965-
Mishra, Sandipan

Department(s)

Mechanical and Aerospace Engineering

Degree Name

Ph. D. in Mechanical Engineering

Publisher

Missouri University of Science and Technology

Publication Date

Spring 2024

Pagination

ix, 113 pages

Note about bibliography

Includes_bibliographical_references_(pages 35, 75, 106 and 111-112)

Rights

© 2023 Xin Wang, All rights reserved

Document Type

Dissertation - Open Access

File Type

text

Language

English

Thesis Number

T 12348

Electronic OCLC #

1427274290

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