DEPOSITION STRATEGIES AND PROGRAMMING TO ADDRESS THE MANUFACTURE OF COMPLEX GEOMETRY PARTS BY WAAM (WIRE AND ARC ADDITIVE MANUFACTURING

This work analyzes the factors that affect the manufacture of complex geometry parts by WAAM (Wire and arc additive manufacturing) with the aim of minimizing the material used, improving the Buy-to-Fly ratio (ratio of raw material weight divided by the weight of the final component) and avoiding part distortions. A study of the different material deposition strategies to manufacture the parts (straight beads, circular path beads, serpentine, overlapping beads...) has been carried out to obtain the desired geometry. Depending on the deposition strategy to be used and the geometry of the part, the best option for the definition of robot trajectories has been analyzed, which can be done by direct programming of the robot or in a CAD-CAM design environment. Another aspect to be considered in manufacturing is the time between layers. This time affects the growth of the parts, since the accumulated heat can cause the growth to be inconsistent and generate distortions. To see the effects of different waiting times, simulation tools have been used. Finally, in order to control the deviations of the real part with respect to the theoretical one, the option of using profilometry has been analysed. This paper aims to analyse the development of new methodologies that respond to the different challenges mentioned above.) Keywords: WAAM, Buy-to-Fly, deposition strategies, robot trajectories, simulation