A Process Map for Consistent Build Conditions in the Solid Freeform Fabrication of Thin-Walled Structures

2000 ◽  
Vol 123 (4) ◽  
pp. 615-622 ◽  
Author(s):  
Aditad Vasinonta ◽  
Jack L. Beuth ◽  
Michelle L. Griffith
Keyword(s):  
Solid Freeform Fabrication ◽  
Numerical Models ◽  
Thermal Control ◽  
Process Map ◽  
Freeform Fabrication ◽  
Thin Walled Structures ◽  
Melt Pool ◽  
Material Deposition ◽  
Thin Walled ◽  
Net Shaping

In solid freeform fabrication (SFF) processes involving thermal deposition, thermal control of the process is critical for obtaining consistent build conditions and in limiting residual stress-induced warping of parts. In this research, a nondimensionalized plot (termed a process map) is developed from numerical models of laser-based material deposition of thin-walled structures. This process map quantifies the effects of changes in wall height, laser power, deposition speed and part preheating on melt pool length, which is an essential process parameter to control in order to obtain consistent build conditions. The principal application of this work is to the Laser Engineered Net Shaping (LENS) process under development at Sandia Laboratories; however, the general approach and a subset of the presented results are applicable to any SFF process involving a moving heat source. Procedures are detailed for using the process map to predict melt pool length and predictions are compared against experimentally measured melt pool lengths for stainless steel deposition in the LENS process.

Distributed-Parameter Modeling for Geometry Control of Manufacturing Processes With Material Deposition

1998 ◽  
Vol 122 (1) ◽  
pp. 71-77 ◽  
Author(s):  
Charalabos Doumanidis ◽  
Eleni Skordeli
Keyword(s):  
Solid Freeform Fabrication ◽  
Surface Topology ◽  
Distributed Parameter ◽  
Surface Geometry ◽  
Mass Source ◽  
Freeform Fabrication ◽  
Geometry Model ◽  
Material Deposition ◽  
Solid Objects ◽  
3D Solid

Recent solid freeform fabrication methods generate 3D solid objects by material deposition in successive layers made of adjacent beads. Besides numerical simulation, this article introduces an analytical model of such material addition, using superposition of unit deposition distributions, composed of elementary spherical primitives consistent with the mass transfer physics. This real-time surface geometry model, with its parameters identified by in-process profile measurements, is used for Smith-prediction of the material shape in the unobservable deposition region. The model offers the basis for a distributed-parameter geometry control scheme to obtain a desired surface topology, by modulating the feed and motion of a moving mass source. The model was experimentally tested on a fused wire deposition welding station, using optical sensing by a scanning laser stripe. Its applications to other rapid prototyping methods are discussed. [S0022-0434(00)02301-7]

scholarly journals Experimental Nondestructive Test for Estimation of Buckling Load on Unstiffened Cylindrical Shells Using Vibration Correlation Technique

2015 ◽  
Vol 2015 ◽  
pp. 1-8 ◽  
Author(s):  
Kaspars Kalnins ◽  
Mariano A. Arbelo ◽  
Olgerts Ozolins ◽  
Eduards Skukis ◽  
Saullo G. P. Castro ◽  
...  
Keyword(s):  
Large Scale ◽  
Numerical Models ◽  
Cylindrical Shells ◽  
Laser Scanner ◽  
Experimental Tests ◽  
Buckling Load ◽  
Correlation Technique ◽  
Thin Walled Structures ◽  
Instability Point ◽  
Thin Walled

Nondestructive methods, to calculate the buckling load of imperfection sensitive thin-walled structures, such as large-scale aerospace structures, are one of the most important techniques for the evaluation of new structures and validation of numerical models. The vibration correlation technique (VCT) allows determining the buckling load for several types of structures without reaching the instability point, but this technique is still under development for thin-walled plates and shells. This paper presents and discusses an experimental verification of a novel approach using vibration correlation technique for the prediction of realistic buckling loads of unstiffened cylindrical shells loaded under axial compression. Four different test structures were manufactured and loaded up to buckling: two composite laminated cylindrical shells and two stainless steel cylinders. In order to characterize a relationship with the applied load, the first natural frequency of vibration and mode shape is measured during testing using a 3D laser scanner. The proposed vibration correlation technique allows one to predict the experimental buckling load with a very good approximation without actually reaching the instability point. Additional experimental tests and numerical models are currently under development to further validate the proposed approach for composite and metallic conical structures.

Modeling the Varying Dynamics of Thin-Walled Aerospace Structures for Fixture Design Using Genetic Algorithms

2011 ◽  
Vol 223 ◽  
pp. 652-661
Author(s):  
Mouhab Meshreki ◽  
Helmi Attia ◽  
József Kövecses
Keyword(s):  
Numerical Models ◽  
Research Work ◽  
Computational Effort ◽  
Computational Time ◽  
Fixture Design ◽  
Structural Elements ◽  
Thin Walled Structures ◽  
Thin Walled ◽  
High Flexibility ◽  
High Level

Fixture design for milling of aerospace thin-walled structures is a challenging process due to the high flexibility of the structure and the nonlinear interaction between the forces and the system dynamics. At the same time, the industry is aiming at achieving tight tolerances while maintaining a high level of productivity. Numerical models based on FEM have been developed to simulate the dynamics of thin-walled structures and the effect of the fixture layout. These models require an extensive computational effort, which makes their use for optimization very unpractical. In this research work, a new concept is introduced by using a multi-span plate with torsional and translational springs to simulate the varying dynamics of thin-walled structure during machining. A formulation, based on holonomic constraints, was developed and implemented to take into account the effect of rigid fixture supports. The developed model, which reduces the computational time by one to two orders of magnitude as compared to FE models, is used to predict the dynamic response of complex aerospace structural elements including pockets and ribs while taking into account different fixture layouts. The model predictions are validated numerically. The developed model meets the conflicting requirements of prediction accuracy and computational efficiency.

scholarly journals Laboratory and Numerical Analysis of Steel Cold-Formed Sigma Beams Retrofitted by Bonded CFRP Tapes—Extended Research

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4960
Author(s):  
Ilona Szewczak ◽  
Katarzyna Rzeszut ◽  
Patryk Rozylo ◽  
Malgorzata Snela
Keyword(s):  
Laboratory Tests ◽  
Numerical Models ◽  
Main Idea ◽  
Steel Beams ◽  
Bottom Flange ◽  
Large Rotation ◽  
Thin Walled Structures ◽  
Four Point Bending ◽  
Thin Walled ◽  
The Impact

The presented research is a part of a broader study of strengthening methods closely associated with cold-formed sigma steel beams with tapes made of Carbon Fiber Reinforcement Polymer/Plastic (CFRP). The presented results are a continuation and extension of the tests described in previous work by the authors and refer to high-slenderness thin-walled steel sigma beams subjected to a significant large rotation. The main idea of this expanded study was to identify the effectiveness of CFRP tapes with respect to different locations, namely at a bottom-tensioned or upper-compressed flange. Six beams with a cross-section of an Σ140 × 70 × 2.5 profile by “Blachy Pruszyński” and made of S350GD steel with a span of L = 270 cm were tested in the four-point bending scheme. Two beams, taken as reference, were tested without reinforcement. The remaining beams were reinforced with the use of a 50-mm wide and 1.2-mm thick Sika CarboDur S512 CFRP tape, with two beams reinforced by placing the tape on the upper flange and two with tape located on the bottom flange. The CFRP tape was bonded directly to the beams (by SikaDur®-30 adhesive). Laboratory tests were aimed at determining the impact of the use of composite tapes on the limitation of displacements and deformations of thin-walled structures. In order to perform a precise measurement of displacement, which is, in the case of beams subjected to large rotations, a very difficult issue in itself, the Tritop system and two coupled lenses of the Aramis system were used. Electrofusion strain gauges were used to measure the deformation. In the next step, numerical models of the analyzed beams were developed in the Abaqus program. Good compliance of the results of laboratory tests and numerical analyses was achieved. The obtained results confirm the beneficial effect of the use of tapes (CFRP) on the reduction in displacements and deformations of steel cold-formed elements.

scholarly journals Fem and Experimental Analysis of Thin-Walled Composite Elements Under Compression

2017 ◽  
Vol 22 (2) ◽  
pp. 393-402 ◽  
Author(s):  
P. Różyło ◽  
P. Wysmulski ◽  
K. Falkowicz
Keyword(s):  
Numerical Analysis ◽  
Cross Section ◽  
Numerical Models ◽  
Fem Analysis ◽  
Geometrical Parameters ◽  
Loss Of Stability ◽  
Composite Columns ◽  
Thin Walled Structures ◽  
Operating Stability ◽  
Thin Walled

Abstract Thin-walled steel elements in the form of openwork columns with variable geometrical parameters of holes were studied. The samples of thin-walled composite columns were modelled numerically. They were subjected to axial compression to examine their behavior in the critical and post-critical state. The numerical models were articulately supported on the upper and lower edges of the cross-section of the profiles. The numerical analysis was conducted only with respect to the non-linear stability of the structure. The FEM analysis was performed until the material achieved its yield stress. This was done to force the loss of stability by the structures. The numerical analysis was performed using the ABAQUS® software. The numerical analysis was performed only for the elastic range to ensure the operating stability of the tested thin-walled structures.

scholarly journals Numerical Models of the Connection of Thin-Walled Z-Profile Roof Purlins

Materials ◽  
2021 ◽  
Vol 14 (21) ◽  
pp. 6573
Author(s):  
Přemysl Pařenica ◽  
Petr Lehner ◽  
Jiří Brožovský ◽  
Martin Krejsa
Keyword(s):  
Cross Section ◽  
Numerical Models ◽  
Element Model ◽  
Cross Sectional ◽  
Physical Test ◽  
Thin Walled Structures ◽  
Practical Design ◽  
Thin Walled ◽  
Bolt Connection ◽  
Experimental Preparation

High thin-walled purlins of Z cross-section are important elements in steel wide-span structures. Their behaviour is influenced by many variables that need to be examined for every specific case. Their practical design thus requires extended knowledge of their behaviour for the possible configurations and dimensions. Numerical analysis verified by experimental investigation can thus enrich such knowledge. Numerical models have the advantage of repeatability and the ability to offer parametric changes. The parametric study presented shows a detailed description of a finite element model of thin-walled cross-sectional roof purlins connected to other roof elements. Models include various approaches to modelling bolt connection. Two schemes of purlins, with and without cleats, are presented. The results of different approaches in numerical modelling are compared with the results of a physical test on a real structure. The article shows a significant agreement in the case of specific approaches and points out the differences with others. The results can be helpful in terms of how to approach the modelling of thin-walled structures and the effective approach to experimental preparation.

Process Maps for Predicting Residual Stress and Melt Pool Size in the Laser-Based Fabrication of Thin-Walled Structures

2006 ◽  
Vol 129 (1) ◽  
pp. 101-109 ◽  
Author(s):  
Aditad Vasinonta ◽  
Jack L. Beuth ◽  
Michelle Griffith
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Pool Size ◽  
Thermal Gradients ◽  
Manufacturing Strategy ◽  
Process Maps ◽  
Thin Walled Structures ◽  
Melt Pool ◽  
Thin Walled ◽  
Melt Pool Size

Thermomechanical models are presented for the building of thin-walled structures by laser-based solid freeform fabrication (SFF) processes. Thermal simulations are used to develop quasi-non-dimensional plots (termed process maps) that quantify the effects of changes in wall height, laser power, deposition speed, and part preheating on thermal gradients, with the goal of limiting residual stresses in manufactured components. Mechanical simulations are used to demonstrate the link between thermal gradients and maximum final residual stresses. The approach taken is analogous to that taken in previous research by the authors in developing process maps for melt pool length, for maintaining an optimal melt pool size during component fabrication. Process maps are tailored for application to the laser engineered net shaping process; however, the general approach, insights, and conclusions are applicable to most SFF processes involving a moving heat source, and to other laser-based fusion processes. Results from the residual stress simulations identify two mechanisms for reducing residual stresses and quantify maximum stress reductions achievable through manipulation of all process variables. Results from thermal gradient and melt pool length process maps are used to identify a manufacturing strategy for obtaining a consistent melt pool size while limiting residual stress in a thin-walled part.

scholarly journals Advanced Structural and Technological Method of Reducing Distortion in Thin-Walled Welded Structures

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 504
Author(s):  
Piotr Horajski ◽  
Lukasz Bohdal ◽  
Leon Kukielka ◽  
Radoslaw Patyk ◽  
Pawel Kaldunski ◽  
...  
Keyword(s):  
Stress State ◽  
Numerical Models ◽  
Joint Stiffness ◽  
Welding Process ◽  
Technological Changes ◽  
The Finite Element Method ◽  
Gas Tungsten Arc ◽  
Thin Walled Structures ◽  
Thin Walled ◽  
Residual Stresses And Strains

The article presents an innovative method of reducing welding distortions of thin-walled structures by introducing structural and technological changes. The accuracy of the method was demonstrated on the example of welding the stub pipes to the outer surface of a thin-walled tank with large dimensions, made of steel 1.4301 with a wall thickness of 1.5 × 10−3 (m). During traditional Gas Tungsten Arc Welding (GTAW), distortions of the base are formed, the flatness deviation of which was 11.9 × 10−3 (m) and exceeded the permissible standards. As a result of structural and technological changes, not only does the joint stiffness increase, but also a favorable stress state is introduced in the flange, which reduces the local welding stresses. Numerical models were developed using the finite element method (FEM), which were used to analyze the residual stresses and strains pre-welding, in extruded flanges, in transient, and post-welding. The results of the calculations for various flanges heights show that there is a limit height h = 9.2 × 10−3 (m), above which flange cracks during extrusion. A function for calculating the flange height was developed due to the required stress state. The results of numerical calculations were verified experimentally on a designed and built test stand for extrusion the flange. The results of experimental research confirmed the results of numerical simulations. For further tests, bases with a flange h = 6 × 10−3 (m) were used, to which a stub pipe was welded using the GTAW method. After the welding process, the distortion of the base was measured with the ATOS III scanner (GOM a Zeiss company, Oberkochen, Germany). It has been shown that the developed methodology is correct, and the introduced structural and technological changes result in a favorable reduction of welding stresses and a reduction in the flatness deviation of the base in the welded joint to 0.39 × 10−3 (m), which meets the requirements of the standards.

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