A novel robotic cell for the hot forging wire arc additive manufacturing process: Vibration analysis and process parameter investigation

• Robotic cell was developed for Hot Forging Wire Arc Additive Manufacturing (HF-WAAM). • Parameters for WAAM and HF-WAAM were refined to improve part quality and accuracy. • Torch orientation and work area placement significantly affect robot vibrations. • Vibration data were validated using accelerometers and a high-speed vision system. • Recommendations were made to optimize HF-WAAM for industrial applications. This study presents the development and testing of a novel robotic cell designed for Hot Forging Wire Arc Additive Manufacturing (HF-WAAM). The HF-WAAM process integrates hot forging during the material deposition phase, offering improved dimensional accuracy and mechanical properties compared to conventional WAAM processes. A key focus of the research is the impact of robot vibration on the quality of the manufactured parts. Experiments were conducted to analyze process parameters for both WAAM and HF-WAAM, and to evaluate the effects of torch mounting configurations and work area placement on vibration levels. The results indicate that torch orientation and the robot’s work area significantly influence the vibration experienced during the HF-WAAM process, which in turn affects part quality. The study provides valuable insights into refining the HF-WAAM process for industrial applications, ensuring high-quality part production.