A New Approach For Calculating Inherent Strain and Distortion in Additive Manufacturing of Metal Parts

Additive manufacturing (AM) of metallic parts is widely utilized for industrial applications. However, quality issues of the printed parts, including part distortion and cracks caused by high temperature and fast cooling, result in high residual stress. This is a challenge that limits the industry acceptance of AM. To overcome this challenge, a numerical modeling method for predicting part distortion at the design stage plays an important role, and enables design engineers to remove failures before printing, as well as determine the optimal printing process parameters to minimize part deformation. This research proposes an inherent strain-based part deformation prediction method. To determine the inherent strain (IS) value, a micro-scale model for analyzing the temperature distribution is constructed. The IS value is calculated from the temperature gradient. Then, the IS value is used for determining the part deformation. The proposed methodology has been developed and evaluated, using a 316L stainless steel cantilever beam, in both simulations and experimental results.

Correction to: reduced order modeling of selective laser melting: from calibration to parametric part distortion

A Correction to this paper has been published: 10.1007/s12289-021-01638-4

Machining Distortion Minimization of Monolithic Aircraft Parts Based on the Energy Principle

Machining distortion is a recurring problem in the machining of monolithic aircraft parts. This paper aims to study the machining distortion minimization of monolithic aircraft parts. Firstly, the energy principle of machining distortion was analyzed. Then, a rapid prediction model of the final part distortion for beam parts was proposed based on the equivalent stress, and the initial bending strain energy contained in the final part was used to characterize the bending distortion risk of the final part. Numerical simulation and milling experiments verified the effectiveness of the proposed prediction model. The relative error between the experimental and calculated results does not exceed 26.5%. Finally, the influence of initial residual stress fluctuation, part geometry and the part location on part distortion was analyzed from the energy point of view. The obtained results indicated that the expected final part distortion can be minimized by adjusting these three factors.

Numerical Analysis of Machining Part Distortion in Aircraft Aluminum Structures

The inherent residual stresses in the raw materials of large monolithic structural components whereby machining procedures are needed to produce aircraft components, cause deviations, and distortions that are undesired and rise challenges for engineering design and engineering production teams of the aerospace companies. A numerical approach to address part distortion is proposed in this paper. An algorithm was developed and implemented as a finite element subroutine in the software ANSYS APDL, which uses the raw inherent residual stress parameters of the aluminum alloy and the machining locations of a structural specimen to simulate the machining distortion phenomenon in aircraft aluminum structures. This algorithm uses as inputs the finite element mesh of a component, the coefficients of residual stresses functions, and the machining location parameters from where a part is made of a raw material blank. The numerical results predicted the part distortion phenomenon with an Absolute Error of 2.79% with respect to initial experimental measurements of part distortion. Additionally, the proposed approach was used to develop part distortion curves by considering the machining location of the specimen. From these, numerical optimization techniques led to determine the machining location of the representative specimen that attained lower distortions. Such location corresponded to a vertical value around of 3.15 mm for the two simulated residual stresses conditions in the material. An additional measurement was carried out to validate the optimal numerical results and errors below 3% were obtained. Consequently, the proposed approach can be of use to determine, to reduce and to optimize part distortion without further experimental testing in structural aluminum 7050-T7451 alloy aircraft components.