Thermal sensing and heat input control for thin-walled structure building based on numerical simulation for wire and arc additive manufacturing

2020 ◽  
Vol 35 ◽  
pp. 101357
Author(s):  
Takeyuki Abe ◽  
Jun’ichi Kaneko ◽  
Hiroyuki Sasahara
Keyword(s):  
Numerical Simulation ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Structure Building ◽  
Input Control ◽  
Thermal Sensing ◽  
Thin Walled

scholarly journals Numerical Simulation Development and Computational Optimization for Directed Energy Deposition Additive Manufacturing Process

Materials ◽  
2020 ◽  
Vol 13 (11) ◽  
pp. 2666 ◽  
Author(s):  
Abhilash Kiran ◽  
Josef Hodek ◽  
Jaroslav Vavřík ◽  
Miroslav Urbánek ◽  
Jan Džugan
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Thermal Cycle ◽  
Energy Deposition ◽  
Numerical Results ◽  
Computational Time ◽  
Stress Calculation ◽  
Directed Energy

The rapid growth of Additive Manufacturing (AM) in the past decade has demonstrated a significant potential in cost-effective production with a superior quality product. A numerical simulation is a steep way to learn and improve the product quality, life cycle, and production cost. To cope with the growing AM field, researchers are exploring different techniques, methods, models to simulate the AM process efficiently. The goal is to develop a thermo-mechanical weld model for the Directed Energy Deposition (DED) process for 316L stainless steel at an efficient computational cost targeting to model large AM parts in residual stress calculation. To adapt the weld model to the DED simulation, single and multi-track thermal simulations were carried out. Numerical results were validated by the DED experiment. A good agreement was found between predicted temperature trends for numerical simulation and experimental results. A large number of weld tracks in the 3D solid AM parts make the finite element process simulation challenging in terms of computational time and large amounts of data management. The method of activating elements layer by layer and introducing heat in a cyclic manner called a thermal cycle heat input was applied. Thermal cycle heat input reduces the computational time considerably. The numerical results were compared to the experimental data for thermal and residual stress analyses. A lumping of layers strategy was implemented to reduce further computational time. The different number of lumping layers was analyzed to define the limit of lumping to retain accuracy in the residual stress calculation. The lumped layers residual stress calculation was validated by the contour cut method in the deposited sample. Thermal behavior and residual stress prediction for the different numbers of a lumped layer were examined and reported computational time reduction.

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

2021 ◽  
pp. 095440622199840
Author(s):  
Yashwant Koli ◽  
N Yuvaraj ◽  
Aravindan Sivanandam ◽  
Vipin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Large Scale ◽  
High Deposition Rate ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Geometrical Shapes ◽  
Wire Arc Additive Manufacturing

Nowadays, rapid prototyping is an emerging trend that is followed by industries and auto sector on a large scale which produces intricate geometrical shapes for industrial applications. The wire arc additive manufacturing (WAAM) technique produces large scale industrial products which having intricate geometrical shapes, which is fabricated by layer by layer metal deposition. In this paper, the CMT technique is used to fabricate single-walled WAAM samples. CMT has a high deposition rate, lower thermal heat input and high cladding efficiency characteristics. Humping is a common defect encountered in the WAAM method which not only deteriorates the bead geometry/weld aesthetics but also limits the positional capability in the process. Humping defect also plays a vital role in the reduction of hardness and tensile strength of the fabricated WAAM sample. The humping defect can be controlled by using low heat input parameters which ultimately improves the mechanical properties of WAAM samples. Two types of path planning directions namely uni-directional and bi-directional are adopted in this paper. Results show that the optimum WAAM sample can be achieved by adopting a bi-directional strategy and operating with lower heat input process parameters. This avoids both material wastage and humping defect of the fabricated samples.

scholarly journals VOLCO-X: numerical simulation of material distribution and voids in extrusion additive manufacturing

2021 ◽  
pp. 101900
Author(s):  
Rafael Quelho de Macedo ◽  
Rafael Thiago Luiz Ferreira ◽  
Andrew Gleadall ◽  
Ian Ashcroft
Keyword(s):  
Numerical Simulation ◽  
Additive Manufacturing ◽  
Material Distribution

scholarly journals Influence of Duty Ratio and Current Mode on Robot 316L Stainless Steel Arc Additive Manufacturing

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 508
Author(s):  
Ping Yao ◽  
Hongyan Lin ◽  
Wei Wu ◽  
Heqing Tang
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Low Frequency ◽  
Single Pulse ◽  
Pulse Mode ◽  
Double Pulse ◽  
Duty Ratio ◽  
Utilization Rate ◽  
Specimen Height

Wire and arc additive manufacturing (WAAM) is usually for fabricating components due to its low equipment cost, high material utilization rate and cladding efficiency. However, its applications are limited by the large heat input decided by process parameters. Here, four 50-layer stainless steel parts with double-pulse and single-pulse metal inert gas (MIG) welding modes were deposited, and the effect of different duty ratios and current modes on morphology, microstructure, and performance was analyzed. The results demonstrate that the low frequency of the double-pulse had the effect of stirring the molten pool; therefore, the double-pulse mode parts presented a bigger width and smaller height, finer microstructure and better properties than the single-pulse mode. Furthermore, increasing the duty ratio from 35% to 65% enlarged the heat input, which then decreased the specimen height, increased the width, and decreased the hardness and the tensile strength.

scholarly journals Application of an Additive Manufactured Hybrid Metal/Composite Shock Absorber Panel to a Military Seat Ejection System

2021 ◽  
Vol 11 (14) ◽  
pp. 6473
Author(s):  
Valerio Acanfora ◽  
Chiara Corvino ◽  
Salvatore Saputo ◽  
Andrea Sellitto ◽  
Aniello Riccio
Keyword(s):  
Numerical Simulation ◽  
Additive Manufacturing ◽  
Total Mass ◽  
Shock Absorber ◽  
Metal Composite ◽  
Plastic Deformations ◽  
Shock Absorbers ◽  
Numerical Assessment ◽  
Lattice Core ◽  
Ejection Phase

In this work, a preliminary numerical assessment on the application of an additive manufactured hybrid metal/composite shock absorber panels to a military seat ejection system, has been carried out. The innovative character of the shock absorber concept investigated is that the absorbing system has a thickness of only 6 mm and is composed of a pyramid-shaped lattice core that, due to its small size, can only be achieved by additive manufacturing. The mechanical behaviour of these shock absorber panels has been examined by measuring their ability to absorb and dissipate the energy generated during the ejection phase into plastic deformations, thus reducing the loads acting on pilots. In this paper the effectiveness of a system composed of five hybrid shock absorbers, with very thin thickness in order to be easily integrated between the seat and the aircraft floor, has been numerically studied by assessing their ability to absorb the energy generated during the primary ejection phase. To accomplish this, a numerical simulation of the explosion has been performed and the energy absorbed by the shock-absorbing mechanism has been assessed. The performed analysis demonstrated that the panels can absorb more than 60% of the energy generated during the explosion event while increasing the total mass of the pilot-seat system by just 0.8%.

scholarly journals Study on the Effect of Heat-Input on the Thickness of the Heat-Affected Zone of the SUS316L Steel Welded Joint by Numerical Simulation

2021 ◽  
Vol 31 (5) ◽  
pp. 68-74
Keyword(s):  
Numerical Simulation ◽  
Heat Affected Zone ◽  
Heat Input ◽  
Welded Joint ◽  
Plate Thickness ◽  
Great Influence ◽  
Thickness Direction ◽  
Welding Joint ◽  
Simulation Results ◽  
The Right

The thickness of the heat-affected zone (HAZ) has a great influence on the strength of the welded joint, so one of the important tasks is to control the HAZ to a small enough level, through using the suitable heat-input (qd). In this study, the authors use SYSWELD software to compute and build a relationship between the heat-input and the thickness of the heat-affected zone in the plate thickness direction to find the right heat-input for researched welding joint. The simulation results show that when welding the root pass with qd > 552 J/mm and the cap pass with 754 J/mm < qd < 1066 J/mm, the thickness of HAZ were increased with a function almost linearly.

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