scholarly journals Determination of residual stresses in objects at their additive manufacturing by layer-by-layer photopolymerization method

2018 ◽  
Vol 991 ◽  
pp. 012016
Author(s):  
P S Bychkov ◽  
A V Chentsov ◽  
V M Kozintsev ◽  
A L Popov
Keyword(s):  
Additive Manufacturing ◽  
Residual Stresses ◽  
Layer By Layer

DESTRUCTIVE METHODS FOR DETERMINING RESIDUAL STRESSES (review)

2021 ◽  
pp. 95-104
Author(s):  
A.D. Monakhov ◽  
◽  
N.O. Yakovlev ◽  
V.V. Avtaev ◽  
E.A. Kotova ◽  
...  
Keyword(s):  
Digital Image Correlation ◽  
Residual Stresses ◽  
Speckle Interferometry ◽  
Image Correlation ◽  
Strain Gauges ◽  
Contact Method ◽  
Layer By Layer ◽  
Deep Hole ◽  
Destructive Methods

The paper presents an overview of methods for determining residual stresses. Methods such as splitting and segmentation, layer-by-layer removal, slitting (cutting, pliability), profiling, drilling holes (including a «deep» hole) are considered. The description of the methods for mea-suring the deformation used in the determination of residual stresses is given. The most common contact method using strain gauges, as well as non-contact methods: polarization-optical (photo-elasticity), optical speckle interferometry, digital image correlation.

scholarly journals Taking into account thermal residual stresses in topology optimization of structures built by additive manufacturing

2018 ◽  
Vol 28 (12) ◽  
pp. 2313-2366 ◽  
Author(s):  
Grégoire Allaire ◽  
Lukas Jakabčin
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Heat Fluxes ◽  
Powder Layer ◽  
Layer By Layer ◽  
Thermal Deformations ◽  
Thermal Residual Stresses ◽  
Structural Design Optimization ◽  
Manufacturing Techniques

We introduce a model and several constraints for shape and topology optimization of structures, built by additive manufacturing techniques. The goal of these constraints is to take into account the thermal residual stresses or the thermal deformations, generated by processes like Selective Laser Melting, right from the beginning of the structural design optimization. In other words, the structure is optimized concurrently for its final use and for its behavior during the layer-by-layer production process. It is well known that metallic additive manufacturing generates very high temperatures and heat fluxes, which in turn yield thermal deformations that may prevent the coating of a new powder layer, or thermal residual stresses that may hinder the mechanical properties of the final design. Our proposed constraints are targeted to avoid these undesired effects. Shape derivatives are computed by an adjoint method and are incorporated into a level set numerical optimization algorithm. Several 2D and 3D numerical examples demonstrate the interest and effectiveness of our approach.

scholarly journals History Reduction by Lumping for Time-Efficient Simulation of Additive Manufacturing

Metals ◽  
2019 ◽  
Vol 10 (1) ◽  
pp. 58 ◽  
Author(s):  
Andreas Malmelöv ◽  
Andreas Lundbäck ◽  
Lars-Erik Lindgren
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Energy Deposition ◽  
Computation Time ◽  
Layer By Layer ◽  
Efficient Simulation ◽  
Computational Welding Mechanics ◽  
Directed Energy ◽  
Short Time

Additive manufacturing is the process by which material is added layer by layer. In most cases, many layers are added, and the passes are lengthy relative to their thicknesses and widths. This makes finite element simulations of the process computationally demanding owing to the short time steps and large number of elements. The classical lumping approach in computational welding mechanics, popular in the 80s, is therefore, of renewed interest and is evaluated in this work. The method of lumping means that welds are merged. This allows fewer time steps and a coarser mesh. It was found that the computation time can be reduced considerably, with retained accuracy for the resulting temperatures and deformations. The residual stresses become, to a certain degree, smaller. The simulations were validated against a directed energy deposition (DED) experiment with alloy 625.

Determination of Residual Stresses in Products in Additive Production by the Layer-by-Layer Photopolymerization Method

2017 ◽  
Vol 52 (5) ◽  
pp. 524-529 ◽  
Author(s):  
P. S. Bychkov ◽  
V. M. Kozintsev ◽  
A. V. Manzhirov ◽  
A. L. Popov
Keyword(s):  
Residual Stresses ◽  
Layer By Layer ◽  
Additive Production

DETERMINATION OF RESIDUAL STRESSES AND STRESS INTENSITY FACTORS BY REMOVING LOCAL MATERIAL

2017 ◽  
Vol 48 (4) ◽  
pp. 377-398
Author(s):  
Svyatoslav Igorevich Eleonskii ◽  
Igor Nikolaevich Odintsev ◽  
Vladimir Sergeevich Pisarev ◽  
Stanislav Mikhailovich Usov
Keyword(s):  
Stress Intensity ◽  
Residual Stresses ◽  
Stress Intensity Factors ◽  
Intensity Factors ◽  
Local Material

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 Contactless temperature measurement in wire-based electron beam additive manufacturing Ti-6Al-4V

2021 ◽  
Author(s):  
F. Pixner ◽  
R. Buzolin ◽  
S. Schönfelder ◽  
D. Theuermann ◽  
F. Warchomicka ◽  
...  
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Thermal Imaging ◽  
Temperature Profiles ◽  
Layer By Layer ◽  
Thermal Cycles ◽  
Cooling Rates ◽  
Geometric Boundary ◽  
Microstructural Characterisation ◽  
Local Misorientation

AbstractThe complex thermal cycles and temperature distributions observed in additive manufacturing (AM) are of particular interest as these define the microstructure and the associated properties of the part being built. Due to the intrinsic, layer-by-layer material stacking performed, contact methods to measure temperature are not suitable, and contactless methods need to be considered. Contactless infrared irradiation techniques were applied by carrying out thermal imaging and point measurement methods using pyrometers to determine the spatial and temporal temperature distribution in wire-based electron beam AM. Due to the vacuum, additional challenges such as element evaporation must be overcome and additional shielding measures were taken to avoid interference with the contactless techniques. The emissivities were calibrated by thermocouple readings and geometric boundary conditions. Thermal cycles and temperature profiles were recorded during deposition; the temperature gradients are described and the associated temperature transients are derived. In the temperature range of the α+β field, the cooling rates fall within the range of 180 to 350 °C/s, and the microstructural characterisation indicates an associated expected transformation of β→α'+α with corresponding cooling rates. Fine acicular α and α’ formed and local misorientation was observed within α as a result of the temperature gradient and the formation of the α’.

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