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Modelling and prediction of surface roughness in wire arc additive manufacturing using machine learning

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Abstract

WAAM has been proven a promising alternative to fabricate medium and large scale metal parts with a high depositing rate and automation level. However, the production quality may deteriorate due to the poor deposited layer surface quality. In this paper, a laser sensor based surface roughness measuring method was developed for WAAM. To improve the surface integrity of deposited layers by WAAM, different machine learning models, including ANFIS, ELM and SVR, were developed to predict the surface roughness. Furthermore, the ANFIS model was optimized by GA and PSO algorithms. Full factorial experiments were conducted to obtain the training data, and the K-fold Cross-validation strategy was applied to train and validate machine learning models. The comparison results indicate that GA–ANFIS has superiority in predicting surface roughness. The RMSE, \( R^{2} \), MAE and MAPE for GA–ANFIS were 0.0694, 0.93516, 0.0574, 14.15% respectively. This study could also provide inspiration and guidance for surface roughness modelling in multipass arc welding and cladding.

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Abbreviations

WAAM:

Wire arc additive manufacturing

ANFIS:

Adaptive neuro-fuzzy inference system

GA:

Genetic algorithm

PSO:

Particle swarm optimization

ELM:

Extreme learning machine

SVR:

Support vector regression

WFS:

Wire feed speed

RMSE:

Root mean square error

MAE:

Mean absolute error

MAPE:

Mean absolute percentage error

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Acknowledgements

The authors gratefully acknowledge the China Scholarship Council for financial support (No. 201704910782) and UOW Welding and Industrial Automation Research Centre.

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Authors and Affiliations

  1. School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Northfields Ave, Wollongong, NSW, 2522, Australia

    Chunyang Xia, Zengxi Pan, Joseph Polden & Huijun Li

  2. School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Chunyang Xia, Yanling Xu & Shanben Chen

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  1. Chunyang Xia
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  2. Zengxi Pan
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  3. Joseph Polden
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  4. Huijun Li
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  5. Yanling Xu
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  6. Shanben Chen
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Correspondence to Zengxi Pan or Yanling Xu.

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Xia, C., Pan, Z., Polden, J. et al. Modelling and prediction of surface roughness in wire arc additive manufacturing using machine learning. J Intell Manuf 33, 1467–1482 (2022). https://doi.org/10.1007/s10845-020-01725-4

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  • DOI: https://doi.org/10.1007/s10845-020-01725-4

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