The well-distributed volumetric heat source model for numerical simulation of wire arc additive manufacturing process

2021 ◽  
pp. 102430
Author(s):  
Donghong Ding ◽  
Shimin Zhang ◽  
Qinghua Lu ◽  
Zengxi Pan ◽  
Huijun Li ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Additive Manufacturing ◽  
Heat Source ◽  
Manufacturing Process ◽  
Source Model ◽  
Heat Source Model ◽  
Volumetric Heat Source ◽  
Wire Arc Additive Manufacturing

scholarly journals A Volumetric Heat Source Model for Thermal Modeling of Additive Manufacturing of Metals

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1406
Author(s):  
Yabin Yang ◽  
Xin Zhou
Keyword(s):  
Additive Manufacturing ◽  
Heat Source ◽  
Computational Efficiency ◽  
Thermal Modeling ◽  
Single Layer ◽  
Source Model ◽  
Heat Source Model ◽  
Volumetric Heat Source ◽  
Proposed Model ◽  
High Computational Efficiency

In additive manufacturing of metallic materials, an accurate description of the thermal histories of the built part is important for further analysis of the distortions and residual stresses, which is a big issue for additively manufactured metal products. In the present paper, a computationally volumetric heat source model based on a semianalytical thermal modeling approach is proposed. The proposed model is applied to model the thermal response during a selective laser melting (SLM) process. The interaction between the laser and the material is described using a moving volumetric heat source. High computational efficiency can be achieved with considerable accuracy. Several case studies are conducted to examine the accuracy of the proposed model. By comparing with the experimentally measured melt-pool dimensions, it is found that the error between the predictions obtained by the proposed model and the experimental results can be controlled to less than 10%. High computational efficiency can also be achieved for the proposed model. It is shown that for simulating the thermal process of scanning a single layer with the dimension of 2 mm × 2 mm, the calculation can be finished in around 110 s.

Numerical and Experimental Studies of Residual Stresses in Multipass Welding of High Strength Shipbuilding Steel

2015 ◽  
Vol 59 (03) ◽  
pp. 133-144
Author(s):  
Guangming Fu ◽  
Tetyana Gurova ◽  
Marcelo I. Lourenco ◽  
Segen F. Estefen
Keyword(s):  
Neural Network ◽  
Numerical Simulation ◽  
Heat Source ◽  
Residual Stresses ◽  
Experimental Studies ◽  
Source Model ◽  
Fe Model ◽  
Offshore Platforms ◽  
Heat Source Model ◽  
Shipbuilding Industry

The article contributes, through numerical simulation based on models calibrated by experimental results, to better estimate residual stresses and distortions in welded structures representatives of ships and offshore platforms considering welding procedures relevant to shipyard current practices. A multi-pass welding is carried out to investigate the residual stresses in laboratory tests. The temperature at several positions on a plate sample is recorded with thermocouples and residual stresses are measured using an x-ray diffraction technique. Finite element (FE) models are developed in this study and experimentally validated. The three dimensional (3D) moving Goldak's double-ellipsoidal heat source model is employed in the simulations. A Levenberg-Marquardt neural network algorithm is employed to determine the geometric parameters of the heat source model. The technique based on neural network is applied to dimension the heat source later employed in the thermal analysis using 2D FE model to reduce the computer time of the numerical simulation and to make it feasible for shipbuilding industry applications. The numerical results of temperature and residual stress distribution are correlated with the experimental measurements. Finally, the effects of preheat and interpass temperatures on the residual stresses are investigated using numerical simulation. The effects of the transient releasing temperature on the residual stresses are also discussed.

scholarly journals Numerical Analysis of the Influence of Electrode Inclination on Temperature Distribution during GMAW Overlaying

2019 ◽  
Vol 2019 ◽  
pp. 1-13 ◽  
Author(s):  
Jerzy Winczek ◽  
Marek Gucwa ◽  
Miloš Mičian ◽  
Krzysztof Makles
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Theoretical Model ◽  
Temperature Distribution ◽  
Numerical Analysis ◽  
Heat Source ◽  
Analytical Description ◽  
Source Model ◽  
Heat Source Model ◽  
Inclination Angles

In the work, an analysis of the influence of electrode inclination on the distribution of temperature in the weld overlaying has been conducted. In the analytical description of the temperature field, a volumetric heat source model with an inclined axis with respect to the direction of surfacing was adopted. In the numerical simulation, the own theoretical model of heat source, algorithm, and program performed in the Borland Delphi environment were used. In the calculation examples, different electrode inclination angles were adopted in relation to the welded plate, in the direction of surfacing, opposite to the direction of welding, and perpendicular to the weld bead.

scholarly journals Heat source management in wire-arc additive manufacturing process for Al-Mg and Al-Si alloys

2019 ◽  
Vol 26 ◽  
pp. 180-192 ◽  
Author(s):  
Kohei Oyama ◽  
Spyros Diplas ◽  
Mohammed M'hamdi ◽  
Anette E. Gunnæs ◽  
Amin S. Azar
Keyword(s):  
Additive Manufacturing ◽  
Heat Source ◽  
Manufacturing Process ◽  
Wire Arc Additive Manufacturing ◽  
Source Management

scholarly journals Numerical Analysis and Experimental Verification of Optimum Heat Input in Additive Manufacturing of Aero Ultrathin Blade

2021 ◽  
Vol 2021 ◽  
pp. 1-23
Author(s):  
Shijie Dai ◽  
Miao Gong ◽  
Liwen Wang ◽  
Tao Wang
Keyword(s):  
Heat Transfer ◽  
Additive Manufacturing ◽  
Numerical Analysis ◽  
Heat Source ◽  
Heat Input ◽  
Source Model ◽  
Heat Transfer Model ◽  
Transfer Model ◽  
Heat Source Model ◽  
Blade Repair

Heat input is a crucial factor affecting the quality in blade additive manufacturing repairing. First, a moving heat source model was established, and through numerical analysis and experimental comparison, the optimal geometric parameters of the heat source model for ultrathin blade repair were obtained. Second, a heat transfer model is established based on the optimal heat source model. By analyzing the thermophysical properties of different alloys, the heat input range of the blade was calculated. By heat transfer calculation under different heat inputs, the heat transfer model of blade repair was optimized. Then, a mathematical model of additive height is established. The optimized heat transfer model is used to solve the temperature distribution of the additive section with time under different wire feeding speeds through numerical analysis, which further reduced the heat input range. Third, the experiments are carried out based on the results of numerical analysis. The evolution law of the microstructure and heat input rate of the additive manufacturing zone was revealed, and the optimal heat input parameters were obtained. Under the optimal parameters, the segregation zone disappeared; hence, the test data were close to the base metal, and the additive manufacturing zone achieved better quality. The results and methods are of great guiding significance for the optimization design in additive manufacturing repair of the aero blades. The study also contributes to carrying out a series of research on heat transfer of ultrathin nickel-based alloy welding.

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