Prediction of Geometric Dimensions of Deposited Layer Produced Using Laser-Arc Hybrid Additive Manufacturing

Laser-arc hybrid additive manufacturing (LAHAM) holds substantial potential in industrial applications, yet ensuring dimensional accuracy remains a major challenge. Accurate prediction and effective control of the geometrical dimensions of the deposited layers are crucial for achieving this accuracy. The width and height of the deposited layers, key indicators of geometric dimensions, directly affect the forming precision. This study conducted experiments and in-depth analysis to investigate the influence of various process parameters on these dimensions and proposed a predictive model for accurate forecasting. It was found that the width of the deposited layers was positively correlated with laser power and arc current and negatively correlated with scanning speed, while the height was negatively correlated with laser power and scanning speed and positively with arc current. Quantitative analysis using the Taguchi method revealed that the arc current had the most significant impact on the dimensions of the deposited layers, followed by scanning speed, with laser power having the least effect. A predictive model based on extreme gradient boosting (XGBoost) was developed and optimized using particle swarm optimization (PSO) for tuning the number of leaf nodes, learning rate, and regularization coefficients, resulting in the PSO-XGBoost model. Compared to models enhanced with PSO-optimized support vector regression (SVR) and XGBoost, the PSO-XGBoost model exhibited higher accuracy, the smallest relative error, and performed better in terms of Mean Relative Error (MRE), Mean Square Error (MSE), and Coefficient of Determination R² metrics. The high predictive accuracy and minimal error variability of the PSO-XGBoost model demonstrate its effectiveness in capturing the complex nonlinear relationships between process parameters and layer dimensions. This study provides valuable insights for controlling the geometric dimensions of the deposited layers in LAHAM.