An efficient tool-path planning approach for repair of cylindrical components via laser cladding
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An efficient tool-path planning approach for repair of cylindrical components via laser cladding Habiba Zahir Imam 1 & Yufan Zheng 1 & Rafiq Ahmad 1 Received: 5 June 2020 / Accepted: 30 October 2020/ # Springer Nature B.V. 2020
Abstract
Laser metal deposition (LMD) is extensively used for repairing and remanufacturing mechanical components. Amongst these components, the vast majority comprise of cylindrical and planar geometries. In recent remanufacturing work, it is a challenge to generate a deposition tool-path directly from point cloud data of a damaged surface. Additionally, the acquisition of high resolution point cloud data that is necessary to carry out a high precision repair presents another problem since it is a time-consuming process. Hence, this paper explores a novel approach for tool-path generation for the repair of cylindrical components directly from point clouds via LMD technology. The presented method discounts the surface reconstruction and registration steps and directly generates tool-path from the damaged point cloud data. In this paper, a comparison is drawn between the traditional framework of reverse engineering and the proposed approach. Following, a tool-path generation method is presented, which incorporates enhancing the resolution or information density of the point cloud data. Finally, the results are validated through a robot laser cladding system (RLCS), which carries out autonomous repair based on the tool-path algorithm. The proposed method is demonstrated to repair a cylindrical fixed bend. Keywords Reverse engineering . Remanufacturing . Lasercladding . Robotlasercladdingsystem . Tool-path generation . Cylinders
Introduction The manufacturing industry plays a major role in technological advancement and accounts for a large part of the global energy and materials consumption [18]. The majority of components in engineering facilities consist of cylindrical and planar geometries [7]. Cylinders are widely
* Rafiq Ahmad [email protected]
1
Laboratory of Intelligent Manufacturing, Design and Automation (LIMDA). Department of Mechanical Engineering, University of Alberta, Edmonton, Canada
Journal of Remanufacturing
used to produce parts for industrial plants, the construction and automobile sectors in the form of pipelines, drill bits, gas cylinders etc. For manufacturing industries to keep up to par with the rising challenge of sustainability, it is critical to analyze industrial waste and propose new ways to recycle end-of-life components [17]. Worn cylindrical parts contribute a significant amount to this scrap, which is why comprehensible and coherent methods need to be employed to minimize the amount of lost resources. These methods mostly comprise of additive manufacturing technologies to bring the part to as new state and often optimize the components topology for greater longevity [10, 11]. Direct energy deposition (DED) is the most widely used additive repair technology for its advantages which are (1) a smaller heat-affected zone as compared to welding, (2) an
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