|
7390 |
|
Thursday, May 05, 2022, Hall D 2:20 PM Cold Gas Spraying I |
|
Strategies and analyses for robot trajectory optimization in thermal and kinetic spraying |
|
Hongjian Wu* / Helmut Schmidt University of the Federal Armed Forces, Germany Thomas Klassen / Helmut Schmidt University/University of the Federal Armed Forces Hamburg, Germany R. Raoelison/ Université de technologie de Belfort Montbéliard (UTBM), France Hanlin Liao/ Université de technologie de Belfort Montbéliard (UTBM), France S. Deng/ Université de technologie de Belfort Montbéliard (UTBM), France Frank Gärtner/ Helmut Schmidt University/University of the Federal Armed Forces Hamburg, Germany |
|
Applications in thermal and kinetic spraying increasingly aim for coating of parts with complex geometries. So far, respective robot programming for the needed trajectories in deposition is mainly adjusted individually in time consuming procedures. Thus, there are needs for the development of methods that allow a fast adoption to part geometries and production conditions as well as possible quality control. To tackle these problems, the present work addresses novel strategies for robot programming and post spray analyses. The design of methods and work flows follow routes of smart manufacturing and should allow for fast and accurate implementation into spray procedures. The developed application is able to handle complex parts of arbitrary geometry, as supplied by CAD data. The program features include (i) cutting of the objects, and (ii) creating self-intersecting curves for producing a set of index sequence-based spatial discrete points of the substrate to be coated. By reordering the discrete points, an adaptive robot trajectory for deposition is generated. During path planning, boundary conditions as for example perpendicular angles of the spray jet on the part’s surface are considered. Robot offline programming allows for process simulation and optimization of the robot kinematics. The whole procedure was tested for cold spraying onto a complex work piece to verify the capability of this strategy. By optical scanning profilometry, the layer by layer deposit build-up could be monitored for quality control, as well as for the final coating thickness. For the given example, the layer thickness on the given part contours could be kept within deviations of less than ten percent of the nominal thickness. Based on the universal layout of the applied methods, the strategies may be applied for thermal spraying in general, considering individual boundary conditions. With respect to cold spraying, the models provide a good basis for part repair and additive manufacturing. |