Trajectory Planning for Multi-torch Collaborative Additive Manufacturing on Large Cylindrical Parts

XU Liuming; LIU Jie; KONG Xiangli; JI Donglei; XIAO Andong; CHENG Chuanshi

doi:10.3969/j.issn.1674-6457.2026.03.017

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (3) : 156-164. DOI: 10.3969/j.issn.1674-6457.2026.03.017

Additive Manufacturing

Trajectory Planning for Multi-torch Collaborative Additive Manufacturing on Large Cylindrical Parts

XU Liuming, LIU Jie, KONG Xiangli, JI Donglei, XIAO Andong, CHENG Chuanshi^*

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Abstract

The work aims to investigate a trajectory planning strategy for multi-torch collaboration to address the challenges of severe heat accumulation and large residual stress in the surface cladding of large-sized cylindrical parts caused by the single-torch sequential printing path in wire and arc additive manufacturing (WAAM). A multi-torch collaborative WAAM system was designed, consisting of a central rotating axis and four torches arranged at 90° intervals circumferentially. The system operated in three primary modes: rotation of the torches driven by the rotating axis, radial movement of the torches towards or away from the rotation center, and vertical motion of the torches. A space-time distribution index system for the printing trajectory was developed, and an approximate global optimal trajectory sequence planning method was proposed based on a simulated annealing algorithm, designed to balance the distribution of temperature and stress fields during the printing process. Then, a thermo-mechanical coupling simulation of the printing process was performed according to the finite element method. The temperature and stress fields of three trajectory strategies of sequential printing, crosswise printing, and optimized sequence printing were compared. Finally, cylindrical cladding experiments were carried out based on the robot arc additive manufacturing platform. The simulation results showed that the optimized printing sequence yielded the best temperature and stress fields. Compared with traditional adjacent trajectory sequential printing, the optimized sequence reduced peak temperature and peak stress by 19% and 18%, respectively, confirming the effectiveness of the proposed algorithm. Tests were performed on the tensile strength, dimensional accuracy, and metallographic structure of the cladding samples, and promising results were achieved. The trajectory sequence optimization strategy proposed in this study can significantly reduce the maximum temperature and thermal stress during the printing process, with good forming performance and precision. This approach offers valuable insights for trajectory planning in multi-torch cylindrical additive manufacturing.

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wire and arc additive manufacturing / multi-torch collaboration / trajectory planning / trajectory uniformity / thermo-mechanical coupling simulation

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XU Liuming, LIU Jie, KONG Xiangli, JI Donglei, XIAO Andong, CHENG Chuanshi. Trajectory Planning for Multi-torch Collaborative Additive Manufacturing on Large Cylindrical Parts[J]. Journal of Netshape Forming Engineering. 2026, 18(3): 156-164 https://doi.org/10.3969/j.issn.1674-6457.2026.03.017

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