Fixture Layout Optimization for Remanufacturing Using Directed Energy Deposition Process

Paper in proceeding, 2024

Remanufacturing of aero-engine blade components is vital for sustainability and cost-efficiency in aerospace and energy industries. These types of products are sometimes damaged during use but may be successfully repaired using additive manufacturing processes, e.g., Directed Energy Deposition (DED). During this process, precise and reliable fixturing during machining and repairs is crucial as it impacts the final geometric outcome of the remanufactured component. In this study, the fixture layout during the DED process for optimal geometric outcome is considered. Initially, the placement zones in the part surfaces are defined, and the problem space is discretized. A greedy optimization algorithm is considered for the optimization of the clamping positions to achieve the highest geometric quality. The surface on which the material is deposited is measured and analyzed. The optimal fixture layout to achieve minimum deviation on this surface prior to the DED process is identified. The DED process is then simulated, and the deviation in the final geometry is analyzed before and after optimization. Accurate simulation of the DED process using the inherent strain approach allows for verification of the optimization of the fixture layout. The result of this study shows the importance of locating and clamping placement for the remanufacturing process using the DED process.