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Prediction of Selective Laser Melting Part Quality Using Hybrid Bayesian Network

DOI:10.1016/j.addma.2020.101089 期刊:Additive Manufacturing 出版年份:2020 更新时间:2025-09-16 10:30:52
摘要: Additive manufacturing (AM) is gaining popularity because of its ability to manufacture complex parts in less time. Despite recent research involving designs of experiments (DOEs) to characterize the relationships between some AM process parameters and various part quality characteristics, to date, there seems to be no universally accepted comprehensive model that relates process parameters to part quality. In this paper, to support the goal of manufacturing parts right the first time, a Bayesian network in continuous domain is developed which relates four process parameters (laser power, scan speed, hatch spacing, and layer thickness) and five part quality characteristics (density, hardness, top layer surface roughness, ultimate tensile strength in the build direction and ultimate tensile strength perpendicular to the build direction). A machine learning algorithm is used to train the network on a database mined from a large number of publications with experimental data from parts built using 316L with selective laser melting. Using this Bayesian network, the user is able to enter a value for one or more known nodes or variables, and the network provides predictions on all the remaining nodes in the form of probability distributions. A method is developed whereby the user inputs are checked for reasonableness using an ??-dimensional convex hull, and if necessary a recommendation is returned based on user-defined weights. The network is validated by retaining a subset of the training data for testing and comparing the network’s predictions to the known values. Accuracy is optimized by continually re-training the network using parts built with a specific machine of interest. The industrial relevance of this research is outlined with respect to four current challenges in AM, including the length of time to determine optimal process parameters for a new machine, ability to organize relevant knowledge, quantification of machine variability, and transfer of knowledge to new operators.
作者: Nathan Hertlein,Sourabh Deshpande,Vysakh Venugopal,Manish Kumar,Sam Anand
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研究概述 实验方案

To develop a Bayesian network that predicts the quality of parts manufactured using selective laser melting (SLM) by relating process parameters to part quality characteristics, aiming to manufacture parts right the first time.

A Bayesian network with continuous nodes was successfully designed to relate SLM process parameters and part quality, trained using literature data, and validated with experimental data. The network showed the ability to learn the behavior of a new SLM machine with a very small number of test prints, providing predictions within a close range of true values. The method developed for checking observation reasonableness using an ??-dimensional convex hull was effective. The research addresses key industrial challenges in AM, including reducing the time to determine optimal process parameters, organizing relevant knowledge, quantifying machine variability, and facilitating knowledge transfer to new staff.

The study did not directly consider several important process parameters such as laser type, spot size, preheating, and powder diameter, which could improve prediction accuracy if included. The current implementation deals only with bulk properties and does not predict geometrical accuracy and geometric tolerances.

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