Development of tool path planning algorithm for Wire Arc Additive Manufacturing for axisymmetric parts

Additive Manufacturing (AM) has significantly reshaped the industrial sector by enabling the production of intricate and customized components with an unparalleled level of precision. Traditional manufacturing techniques, particularly subtractive processes, often struggle to achieve the same level of design complexity and efficiency. Unlike these conventional methods, AM constructs parts by systematically adding material in successive layers. This unique fabrication approach maximizes design flexibility, minimizes material waste, and enhances production efficiency. As a result, AM has gained widespread adoption in industries such as aerospace and automotive, where lightweight, high-performance components are in constant demand. Among the various AM technologies, Direct Energy Deposition (DED) has emerged as a highly effective method for manufacturing fully functional metal parts while reducing material waste. However, one of the primary challenges in DED, particularly in Wire Arc Additive Manufacturing (WAAM), lies in optimizing tool path planning. This process involves defining the most efficient trajectory for material deposition, ensuring uniform distribution and superior build quality. In WAAM, the effectiveness of the final product depends heavily on the selected deposition strategy, which must be carefully adapted to the geometry of the part being fabricated. This research aims to enhance tool path planning for WAAM, focusing specifically on the development of an algorithm capable of generating optimized deposition paths for axisymmetric components, such as low-pressure turbine casings. The fundamental issue revolves around determining the ideal placement of deposition beads to achieve a uniform structure. To address this, the study proposes the development of a MATLAB-based algorithm that calculates the optimal position of the center points of the beads, ensuring consistent material deposition throughout the construction process. A key reference model in this domain is the overlap model developed by Ding, which predicts the interaction between adjacent beads during the deposition process. This model sets a base for the development of the proposed algorithm. Additionally, many commercially available path-planning software solutions are designed for proprietary machines or materials, restricting their adaptability and broader industrial use. Obviously there are advanced software, but they are very expensive such as Siemens NX Additive which allows the customization of thermal and metallurgical parameters but is designed only for CNC systems and not for ABB or KUKA robots, or Autodesk Powermill Additive for the toolpath of complex geometries. MATLAB has been chosen as the development platform due to its robust numerical computing capabilities and high degree of customization. Unlike many commercial software solutions, MATLAB provides full control over algorithm design and modifications, making it particularly suitable for research and the advancement of specialized WAAM applications. The thesis begins with a comprehensive review of AM innovations and their impact on industrial manufacturing. Then it delves into the significance of DED, with a particular focus on WAAM, before examining one of its most crucial aspects: tool path planning. The ultimate objective is to demonstrate how advancements in path generation strategies can significantly enhance the efficiency, quality, and overall feasibility of WAAM, particularly in the context of fabricating axisymmetric aerospace components.