Online stress monitoring during laser-directed energy deposition based on dynamic contour method
Deformation and cracking caused by internal stress have been a long-standing challenge in the field of metal additive manufacturing. This paper presents a novel method for real-time stress assessment of laser-directed energy deposition (LDED) based on the shrinkage phenomenon of deposition layer – t...
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| Main Authors: | , , , , , , , , |
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| Format: | Article |
| Language: | English |
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2024.2448543 |
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| _version_ | 1841554094639022080 |
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| author | Yi Lu Wenbo Li Jian Dong Chen Wang Rongqi Shen Kelin Zhu Bin Wu Guifang Sun Jing Rao |
| author_facet | Yi Lu Wenbo Li Jian Dong Chen Wang Rongqi Shen Kelin Zhu Bin Wu Guifang Sun Jing Rao |
| author_sort | Yi Lu |
| collection | DOAJ |
| description | Deformation and cracking caused by internal stress have been a long-standing challenge in the field of metal additive manufacturing. This paper presents a novel method for real-time stress assessment of laser-directed energy deposition (LDED) based on the shrinkage phenomenon of deposition layer – the Dynamic Contour Method (DCM). It integrates machine vision, three-dimensional reconstruction based on actual morphology, and numerical simulation to calculate rapidly stress development during the LDED process. Meanwhile, a mapping relationship between the surface shrinkage of the deposition layer and stress is established, providing a theoretical basis for the DCM. Regarding the validation of this method, the DCM simulations are compared with the experimentally calibrated thermo-mechanical coupling simulations. The results show a high degree of consistency, demonstrating the feasibility and accuracy of the DCM. This method provides a new digital twin framework for additive manufacturing. |
| format | Article |
| id | doaj-art-3fc511cca0ed471c9a506ce58410b519 |
| institution | Kabale University |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-3fc511cca0ed471c9a506ce58410b5192025-01-08T21:14:22ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2024.2448543Online stress monitoring during laser-directed energy deposition based on dynamic contour methodYi Lu0Wenbo Li1Jian Dong2Chen Wang3Rongqi Shen4Kelin Zhu5Bin Wu6Guifang Sun7Jing Rao8College of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing, People’s Republic of ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing, People’s Republic of ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing, People’s Republic of ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing, People’s Republic of ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing, People’s Republic of ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing, People’s Republic of ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing, People’s Republic of ChinaSchool of Mechanical Engineering, Southeast University, Nanjing, People’s Republic of ChinaSchool of Instrumentation and Opto-Electronic Engineering, Beihang University, Beijing, People’s Republic of ChinaDeformation and cracking caused by internal stress have been a long-standing challenge in the field of metal additive manufacturing. This paper presents a novel method for real-time stress assessment of laser-directed energy deposition (LDED) based on the shrinkage phenomenon of deposition layer – the Dynamic Contour Method (DCM). It integrates machine vision, three-dimensional reconstruction based on actual morphology, and numerical simulation to calculate rapidly stress development during the LDED process. Meanwhile, a mapping relationship between the surface shrinkage of the deposition layer and stress is established, providing a theoretical basis for the DCM. Regarding the validation of this method, the DCM simulations are compared with the experimentally calibrated thermo-mechanical coupling simulations. The results show a high degree of consistency, demonstrating the feasibility and accuracy of the DCM. This method provides a new digital twin framework for additive manufacturing.https://www.tandfonline.com/doi/10.1080/17452759.2024.2448543Laser-directed energy depositionresidual stressinternal stress monitoringdigital twinmachine visionnumerical simulation |
| spellingShingle | Yi Lu Wenbo Li Jian Dong Chen Wang Rongqi Shen Kelin Zhu Bin Wu Guifang Sun Jing Rao Online stress monitoring during laser-directed energy deposition based on dynamic contour method Virtual and Physical Prototyping Laser-directed energy deposition residual stress internal stress monitoring digital twin machine vision numerical simulation |
| title | Online stress monitoring during laser-directed energy deposition based on dynamic contour method |
| title_full | Online stress monitoring during laser-directed energy deposition based on dynamic contour method |
| title_fullStr | Online stress monitoring during laser-directed energy deposition based on dynamic contour method |
| title_full_unstemmed | Online stress monitoring during laser-directed energy deposition based on dynamic contour method |
| title_short | Online stress monitoring during laser-directed energy deposition based on dynamic contour method |
| title_sort | online stress monitoring during laser directed energy deposition based on dynamic contour method |
| topic | Laser-directed energy deposition residual stress internal stress monitoring digital twin machine vision numerical simulation |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2024.2448543 |
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