Development of a Deep Learning-Based Decision Framework for Optimal Process Parameter Selection in Metal Additive Manufacturing

Conventional subtractive manufacturing methods, such as cutting, often result in material waste and limitations in geometric complexity. To address these challenges, Wire Arc Additive Manufacturing (WAAM), in which components are built through successive weld bead deposition, has attracted increasing attention across various industrial fields. However, WAAM-fabricated components typically exhibit significant surface irregularities, necessitating additional post-processing that reduces overall productivity. Improving productivity therefore requires effective control and optimization of deposition parameters. This task is particularly challenging in multilayer WAAM processes, as the geometry of previously deposited layers varies with operating conditions. To address this challenge, this study proposes an AI-based framework for controlling surface roughness by rapidly identifying near-optimal process parameters in response to evolving bead geometry. A large-scale simulation dataset was generated by applying a pre-trained deep neural network (DNN) surface roughness predictor to one million bead geometry variations under 72 process parameter combinations. The resulting optimal parameter labels were used to train a classification model that recommends process conditions based on the current bead geometry. Model performance was evaluated using predictor-estimated surface roughness values, achieving Weighted Precision, Recall, and F1-score of 0.98, with an average AUC of 0.977. Five previously generated WAAM specimens were used for comparative analysis between AI-recommended and conventional process conditions using the previously developed and validated surface roughness prediction model, rather than direct physical measurements. This predictor-based feasibility analysis showed that AI-recommended conditions consistently reduced the predicted surface roughness, indicating the potential of AI-driven process optimization to improve surface quality in WAAM and reduce reliance on post-processing.