A multi-objective optimization method of directed energy deposition manufacturing process considering carbon emission

• Published in: Journal of cleaner production 2024-05, Vol.452, p.142144, Article 142144
• Main Authors: Liu, Ao, Jiang, Xingyu, Song, Boxue, Chen, Keqiang, Xu, Xiaowen, Yang, Guozhe, Liu, Weijun
• Format: Article
• Language: English
• Subjects: Aspect ratio; Carbon emission; Directed energy deposition; Generalized differential evolution; Multi-objective optimization; Powder utilization rate
• ISSN: 0959-6526; 1879-1786
• DOI: 10.1016/j.jclepro.2024.142144

Due to the increasing necessity for a global reaction to climate change, there is a worldwide emphasis on achieving carbon peaks and carbon neutrality. In particular, optimizing carbon emissions in directed energy deposition manufacturing has gained significant attention. In this study, we analyze the carbon emission characteristics of each system used in directed energy deposition processes. In addition, we formulate an optimization model for the directed energy deposition manufacturing process, focusing on carbon emission reduction, powder utilization rate improvement, and aspect ratio enhancement. A new iteration of the Generalized Differential Evolution 3 algorithm is presented in this study. The enhanced algorithm makes use of chaotic memory weight factors to promote diversity. This approach effectively avoids premature convergence of the algorithm while also increasing the speed of convergence and accuracy of the solution. Experiments are carried out on the platform of LDM4030 directed energy deposition equipment. The results indicate that implementing the proposed model and algorithm in this study resulted in a 25% decrease in carbon emissions during printing of components, a 19% enhancement in powder utilization rate, and a 6% improvement in aspect ratio. The study investigates the influence of the variable on the optimization target through S/N ratio analysis and contour plots. Furthermore, the investigation examines the modifications of a single factor's regulations for the objective, presenting a promising approach for the directed energy deposition manufacturing equipment industry to achieve carbon peak and neutralization.