Machine tool cross beam design, fabrication, and testing using metal big area additive manufacturing

Tyler Poon; Justin L. West; Emma D. Betters; Scott Smith; Christopher T. Tyler; Andrzej Nycz; Christopher Masuo; Tony Schmitz

doi:10.1016/j.mfglet.2024.09.105

Machine tool cross beam design, fabrication, and testing using metal big area additive manufacturing

Tyler Poon, Justin L. West, Emma D. Betters, Scott Smith, Christopher T. Tyler, Andrzej Nycz, Christopher Masuo, Tony Schmitz

Research output: Contribution to journal › Article › peer-review

Abstract

This paper describes the application of metal Big Area Additive Manufacturing (mBAAM) to the fabrication of a machine tool cross beam. The replacement of a traditional box design weldment with a new design printed by wire arc additive manufacturing using the MedUSA system at Oak Ridge National Laboratory (ORNL) is detailed. This requires a new design strategy based on the unique mBAAM capabilities. The intent of the new design is to reduce mass, while maintaining the dynamic stiffness. To compare the two designs, the natural frequencies and mode shapes are measured using impact testing and predicted using finite element analysis. It is confirmed that the printed structure dynamics agreed with the numerical model predictions, which demonstrates that it is feasible to model a large-scale mBAAM part and understand its behavior prior to printing. Another notable outcome of this study is that the significant residual stress and distortion in the print indicate that knowledge gaps remain for widespread implementation of mBAAM.

Original language	English
Pages (from-to)	850-861
Number of pages	12
Journal	Manufacturing Letters
Volume	41
DOIs	https://doi.org/10.1016/j.mfglet.2024.09.105
State	Published - Oct 2024

Funding

This work was partially supported by the DOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (AMO), under contract DE-AC05-00OR22725. The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). The authors knowledge support from the DoD Industrial Base Analysis and Sustainment Program (IBAS). The authors would also like to acknowledge support from the NSF Engineering Research Center for Hybrid Autonomous Manufacturing Moving from Evolution to Revolution (ERC-HAMMER) under Award Number EEC-2133630. The wire-arc technology used to create the cross beam was developed in collaboration with Lincoln Electric under a Cooperative Research and Development Agreement. This work was partially supported by the DOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (AMO) , under contract DE-AC05-00OR22725 . The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). The authors knowledge support from the DoD Industrial Base Analysis and Sustainment Program (IBAS). The authors would also like to acknowledge support from the NSF Engineering Research Center for Hybrid Autonomous Manufacturing Moving from Evolution to Revolution (ERC-HAMMER) under Award Number EEC-2133630 . The wire-arc technology used to create the cross beam was developed in collaboration with Lincoln Electric under a Cooperative Research and Development Agreement.

Funders	Funder number
DOE Public Access Plan
Office of Energy Efficiency and Renewable Energy
U.S. Department of Defense
NSF Engineering Research Center for Hybrid Autonomous Manufacturing Moving
Advanced Manufacturing Office	DE-AC05-00OR22725
ERC-HAMMER	EEC-2133630

Keywords

Additive manufacturing
Finite element analysis
Machine tool
Modal analysis

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.mfglet.2024.09.105

Cite this

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title = "Machine tool cross beam design, fabrication, and testing using metal big area additive manufacturing",

abstract = "This paper describes the application of metal Big Area Additive Manufacturing (mBAAM) to the fabrication of a machine tool cross beam. The replacement of a traditional box design weldment with a new design printed by wire arc additive manufacturing using the MedUSA system at Oak Ridge National Laboratory (ORNL) is detailed. This requires a new design strategy based on the unique mBAAM capabilities. The intent of the new design is to reduce mass, while maintaining the dynamic stiffness. To compare the two designs, the natural frequencies and mode shapes are measured using impact testing and predicted using finite element analysis. It is confirmed that the printed structure dynamics agreed with the numerical model predictions, which demonstrates that it is feasible to model a large-scale mBAAM part and understand its behavior prior to printing. Another notable outcome of this study is that the significant residual stress and distortion in the print indicate that knowledge gaps remain for widespread implementation of mBAAM.",

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author = "Tyler Poon and West, {Justin L.} and Betters, {Emma D.} and Scott Smith and Tyler, {Christopher T.} and Andrzej Nycz and Christopher Masuo and Tony Schmitz",

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doi = "10.1016/j.mfglet.2024.09.105",

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AU - Poon, Tyler

AU - West, Justin L.

AU - Betters, Emma D.

AU - Smith, Scott

AU - Tyler, Christopher T.

AU - Nycz, Andrzej

AU - Masuo, Christopher

AU - Schmitz, Tony

PY - 2024/10

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N2 - This paper describes the application of metal Big Area Additive Manufacturing (mBAAM) to the fabrication of a machine tool cross beam. The replacement of a traditional box design weldment with a new design printed by wire arc additive manufacturing using the MedUSA system at Oak Ridge National Laboratory (ORNL) is detailed. This requires a new design strategy based on the unique mBAAM capabilities. The intent of the new design is to reduce mass, while maintaining the dynamic stiffness. To compare the two designs, the natural frequencies and mode shapes are measured using impact testing and predicted using finite element analysis. It is confirmed that the printed structure dynamics agreed with the numerical model predictions, which demonstrates that it is feasible to model a large-scale mBAAM part and understand its behavior prior to printing. Another notable outcome of this study is that the significant residual stress and distortion in the print indicate that knowledge gaps remain for widespread implementation of mBAAM.

AB - This paper describes the application of metal Big Area Additive Manufacturing (mBAAM) to the fabrication of a machine tool cross beam. The replacement of a traditional box design weldment with a new design printed by wire arc additive manufacturing using the MedUSA system at Oak Ridge National Laboratory (ORNL) is detailed. This requires a new design strategy based on the unique mBAAM capabilities. The intent of the new design is to reduce mass, while maintaining the dynamic stiffness. To compare the two designs, the natural frequencies and mode shapes are measured using impact testing and predicted using finite element analysis. It is confirmed that the printed structure dynamics agreed with the numerical model predictions, which demonstrates that it is feasible to model a large-scale mBAAM part and understand its behavior prior to printing. Another notable outcome of this study is that the significant residual stress and distortion in the print indicate that knowledge gaps remain for widespread implementation of mBAAM.

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Machine tool cross beam design, fabrication, and testing using metal big area additive manufacturing

Abstract

Funding

Keywords

UN SDGs

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