Eventos Anais de eventos
COBEM 2023
27th International Congress of Mechanical Engineering
Development of a Digital Twin for a Robotic Additive Manufacturing System Based on Laser Metal Deposition (LMD) Process
Submission Author:
Alberto Alvares , DF
Co-Authors:
Alberto Alvares, Igor Lacroix, Marco Aurélio Maron, Brayan Stiven Figueroa Betancourth, Lucas de Souza Dantas Amorim Araújo
Presenter: Brayan Stiven Figueroa Betancourth
doi://10.26678/ABCM.COBEM2023.COB2023-0208
Abstract
This work presents a computational architecture and implementation of a Digital Twin (DT) for a robotized additive manufacturing cell that uses the Laser Metal Deposition with wire (LMD-wire) process. The system is composed of an LMD-wire head from Meltio3D and a Kuka KR 70 R2100 robot. The Digital Twin is an Industry 4.0 element that enables new business models and technologies that increase productivity, and decision-making using artificial intelligence, predictive analysis, as well as optimization, simulation, teleoperation, control, and asset management actions. The DT can simulate an operation and identify process failures in advance, thus saving resources and avoiding damage to the machine/process. This becomes even more relevant in emerging technologies such as LMD manufacturing, where a direct energy source based on a Diode Laser, for example, is used to selectively melt a layer of metallic material fed by wire, as in the case at hand, or powder. This manufacturing method has great potential for industrial application but is highly dependent on parameters that need to be optimized to obtain parts with defined prerequisites. Therefore, the creation of a digital twin becomes a great ally of LMD manufacturing, as it can anticipate the existence of errors, as well as track the execution of the part's life cycle and optimize it. To develop the Digital Twin, this work uses ISO 23247 as a reference and the CAD environment Rhinoceros with Grasshopper associated with the Kuka.Sim simulation platform, aiming to develop a CAD/CAPP/CAM (Design, Process Planning, and Additive Manufacturing) platform for the robotized cell using the laser metal deposition head. The Digital Twin should be able to perform 3D modeling of complex parts with different geometries, planning different slicing strategies, planar and non-planar parts, depending on the complexity of the part, simulating the robotized additive manufacturing cell, and generating Kuka KRL (Kuka Robot Language) code in the Rhino/Grasshopper environment. Next, the generated program in the KRL code is sent to the Kuka simulator, Kuka.Sim, which will perform a realistic simulation of the cell, being a Digital Twin of the physical cell. Using Kuka.Sim, which will be one of the elements of the Digital Twin Platform, connecting the physical world (Kuka robot and Meltio LMD) with the digital world, being in perfect harmony and mirroring, in real-time, the physical world to the digital world, the program is executed in the physical world and mirrored to the digital world.
Keywords
Laser Metal Deposition (LMD), Digital Twin, Additive Manufacturing Robotics, ISO 23247, industry 4.0
