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Feature-based energy consumption quantitation strategy for complex additive manufacturing parts

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  • Gao, Mengdi
  • Li, Lei
  • Wang, Qingyang
  • Liu, Conghu
  • Li, Xinyu
  • Liu, Zhifeng

Abstract

Additive manufacturing (AM) has significant advantages, including design freedom, mass customization, and complex-structure manufacturing capabilities. As reducing the manufacturing energy is challenging in terms of the industrial sustainability, the AM energy consumption must be further explored. Existing energy consumption quantitation methods for AM require complex models that considering the energy characteristics of equipment. Therefore, we propose a feature-based energy consumption quantitation method for complex AM parts using simple models and suitable for different AM technologies. First, a feature segmentation method is proposed to divide complex AM parts into typical AM features. Then, the energy consumption model for each AMF is developed for energy consumption quantification during part fabrication. Finally, the energy consumption of a typical mechanical part manufactured via three different AM processes is investigated using the proposed method and measured experimentally. The results show that the proposed method can effectively and rapidly predict the energy consumption of AM processes with an accuracy of more than 95 %. Furthermore, the efficiency of the three AM processes is compared and discussed to address suitable efficiency improvement methods. In general, the proposed method can be integrated into three-dimensional AM models, providing a reference for the structural optimization of AM parts and sustainable manufacturing.

Suggested Citation

  • Gao, Mengdi & Li, Lei & Wang, Qingyang & Liu, Conghu & Li, Xinyu & Liu, Zhifeng, 2024. "Feature-based energy consumption quantitation strategy for complex additive manufacturing parts," Energy, Elsevier, vol. 297(C).
  • Handle: RePEc:eee:energy:v:297:y:2024:i:c:s0360544224010223
    DOI: 10.1016/j.energy.2024.131249
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    References listed on IDEAS

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    1. Xin Xu & Simon Meteyer & Nicolas Perry & Yaoyao Fiona Zhao, 2015. "Energy consumption model of Binder-jetting additive manufacturing processes," International Journal of Production Research, Taylor & Francis Journals, vol. 53(23), pages 7005-7015, December.
    2. Zhiqiang Yan & Jian Huang & Jingxiang Lv & Jizhuang Hui & Ying Liu & Hao Zhang & Enhuai Yin & Qingtao Liu, 2022. "A New Method of Predicting the Energy Consumption of Additive Manufacturing considering the Component Working State," Sustainability, MDPI, vol. 14(7), pages 1-23, March.
    3. Timothy Gutowski & Sheng Jiang & Daniel Cooper & Gero Corman & Michael Hausmann & Jan-Anders Manson & Timo Schudeleit & Konrad Wegener & Matias Sabelle & Jorge Ramos-Grez & Dusan P. Sekulic, 2017. "Note on the Rate and Energy Efficiency Limits for Additive Manufacturing," Journal of Industrial Ecology, Yale University, vol. 21(S1), pages 69-79, November.
    4. Yiran Yang & Lin Li & Yayue Pan & Zeyi Sun, 2017. "Energy Consumption Modeling of Stereolithography-Based Additive Manufacturing Toward Environmental Sustainability," Journal of Industrial Ecology, Yale University, vol. 21(S1), pages 168-178, November.
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