Freeze-form extrusion fabrication is an additive manufacturing process that extrudes high solids loading aqueous ceramic pastes in a layer-by-layer fashion below the paste freezing temperature for component fabrication. Due to effects, such as the air bubble release, agglomerate breakdown, and change in paste properties during extrusion as a result of liquid phase migration, the extrusion force is difficult to control. In this paper, an adaptive controller is proposed to regulate the extrusion force. Recursive least-squares is used to estimate the extrusion force model parameters during fabrication and a low-order control scheme capable of tracking general reference trajectories is designed and implemented to regulate the extrusion process. The controller is implemented for sinusoidal reference trajectories and the results demonstrate excellent tracking performance of the adaptive extrusion force controller. Several parts were fabricated with the adaptive extrusion force controller. These results illustrate the need for extrusion force control and that variable reference extrusion force profiles are required to fabricate complex features.
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December 2010
Technical Briefs
Adaptive Extrusion Force Control of Freeze-Form Extrusion Fabrication Processes
Xiyue Zhao,
Xiyue Zhao
Department of Mechanical and Aerospace Engineering,
e-mail: xzd2c@mst.edu
Missouri University of Science and Technology
, Rolla, MO 65401-0050
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Robert G. Landers,
Robert G. Landers
Department of Mechanical and Aerospace Engineering,
e-mail: landersr@mst.edu
Missouri University of Science and Technology
, Rolla, MO 65401-0050
Search for other works by this author on:
Ming C. Leu
Ming C. Leu
Department of Mechanical and Aerospace Engineering,
e-mail: mleu@mst.edu
Missouri University of Science and Technology
, Rolla, MO 65401-0050
Search for other works by this author on:
Xiyue Zhao
Department of Mechanical and Aerospace Engineering,
Missouri University of Science and Technology
, Rolla, MO 65401-0050e-mail: xzd2c@mst.edu
Robert G. Landers
Department of Mechanical and Aerospace Engineering,
Missouri University of Science and Technology
, Rolla, MO 65401-0050e-mail: landersr@mst.edu
Ming C. Leu
Department of Mechanical and Aerospace Engineering,
Missouri University of Science and Technology
, Rolla, MO 65401-0050e-mail: mleu@mst.edu
J. Manuf. Sci. Eng. Dec 2010, 132(6): 064504 (9 pages)
Published Online: December 17, 2010
Article history
Received:
April 22, 2009
Revised:
October 28, 2010
Online:
December 17, 2010
Published:
December 17, 2010
Citation
Zhao, X., Landers, R. G., and Leu, M. C. (December 17, 2010). "Adaptive Extrusion Force Control of Freeze-Form Extrusion Fabrication Processes." ASME. J. Manuf. Sci. Eng. December 2010; 132(6): 064504. https://doi.org/10.1115/1.4003009
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