Numerical Simulation of the Thermal Behavior during Laser Metal Deposition Shaping Technology

2013 ◽  
Vol 380-384 ◽  
pp. 4327-4331
Author(s):  
Kai Zhang ◽  
Lei Wang ◽  
Xin Min Zhang
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Thermal Behavior ◽  
Fem Simulation ◽  
Thermal Response ◽  
Metal Deposition ◽  
Process Time ◽  
Laser Metal Deposition ◽  
And Control ◽  
Good Agreement

Laser Metal Deposition Shaping (LMDS) is an emerging manufacturing technique that ensures significant reduction of process time between initial design and final components. The fabrication of fully dense parts with appropriate properties using the LMDS process requires an in-depth understanding of the entire thermal behavior of the process. In this paper, the thermal behavior during LMDS was studied, both numerically and experimentally. Temperature distribution and gradient in the fabricated part were obtained by finite element method (FEM) simulation. The numerical results are in good agreement with the experimental observations. The numerical method contributes to the comprehension and control of the thermal behavior, and may be used to optimize process parameters and predict the thermal response of LMDS fabricated components.

Numerical Simulation of Thermal Stress in Castings Using FDM/FEM Integrated Method

2005 ◽  
Vol 490-491 ◽  
pp. 85-90 ◽  
Author(s):  
Xiang Xue ◽  
Jing Tian ◽  
Guoming Xiu
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Residual Stress ◽  
Simulation System ◽  
Stress Evolution ◽  
Practical Application ◽  
Integrated Method ◽  
Stress And Deformation ◽  
Residual Stress And Deformation ◽  
Good Agreement

A numerical simulation system, which integrated FDM (Finite Difference Method) and FEM (Finite Element Method) and coupled temperature field and stress field, was established. This system was then validated by simulation of a stress frame casting. The calculated results are satisfactory and in good agreement with the theoretical analysis. As a practical application, a wave-guide casting was simulated. The stress evolution during casting solidification, residual stress and deformation are predicted.

Springback Prediction Compensation and Optimization for Front Side Member in Sheet Metal Forming Using FEM Simulation

2013 ◽  
Vol 789 ◽  
pp. 436-442
Author(s):  
Agus Dwi Anggono ◽  
Waluyo Adi Siswanto ◽  
Omar Badrul
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Fem Simulation ◽  
Element Size ◽  
Springback Prediction ◽  
Element Method

Numerical simulation by finite element method has become a powerful tool in predicting and preventing the unwanted effects of sheet metals technological processing. One of the most important problems in sheet metal forming is the compensation of springback. To improve the accuracy of the formed parts, the die surfaces are required to be optimized so that after springback the geometry falls at the expected shape. This paper presents and discusses numerical simulation procedure of die compensation by using the methods of Simplified Displacement Adjustment (SDA). This analysis use Benchmark 3 models of Numisheet 2011. Sensitively analysis was done by using finite element method (FEM) show that the springback values are influenced by element size, integration points and material properties.

scholarly journals Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire

2019 ◽  
Vol 9 (23) ◽  
pp. 5115 ◽  
Author(s):  
Yousub Lee ◽  
Yashwanth Bandari ◽  
Peeyush Nandwana ◽  
Brian. T. Gibson ◽  
Brad Richardson ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Residual Stresses ◽  
Material Properties ◽  
Large Scale ◽  
Tool Path ◽  
Metal Deposition ◽  
Cooling Time ◽  
Laser Metal Deposition ◽  
Structural Components ◽  
Part Distortion

Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and efficiency and is suitable for fabrication of large aerospace components. However, control of material properties, geometry, and residual stresses is needed before LMD-w technology can be widely adopted for the construction of critical structural components. In this study, we investigated the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components using finite element method (FEM). The simulations were validated with the temperature and the distortion measurements obtained from a real LMD-w process. We found that a shorter interlayer cooling time, full clamping constraints on the build plates, and a bidirectional tool path with 180° rotation minimized part distortion and residual stresses and resulted in symmetric stress distribution.

Frequency Domain Uncertainty Modeling and Quantification of the Laser Metal Deposition Process

2016 ◽  
Author(s):  
Patrick M. Sammons ◽  
Douglas A. Bristow ◽  
Robert G. Landers
Keyword(s):  
Frequency Domain ◽  
Uncertainty Modeling ◽  
Deposition Process ◽  
Metal Deposition ◽  
Great Promise ◽  
Laser Metal Deposition ◽  
Modeling And Control ◽  
Metal Parts ◽  
Modeling Uncertainties ◽  
And Control

Additive Manufacturing (AM) is a growing class of manufacturing processes where parts are fabricated by repeated addition of material. Many of these processes show great promise for the production of complex, functional parts for use in critical applications. One such process, Laser Metal Deposition (LMD), uses a laser and a coaxial blown metal powder source to produce functional metal parts. However, it has been demonstrated that the LMD process possesses complex two-dimensional dynamics which, when not appropriately accounted for in the modeling and control stages, can lead to build failures. Additionally, even when the two-dimensionality of the process is accounted for, modeling and process uncertainties can lead to degraded performance or instability. Here, in the context of a control oriented model of the LMD process developed previously, process and modeling uncertainties are modeled and quantified in the frequency domain.

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