A novel finite element method for simulating residual stress of TC4 alloy produced by laser additive manufacturing

Zhao, Hongjian; Chen, Yu; Liu, Zihe; Liu, Changsheng; Yu, Zhan

doi:10.1016/j.optlastec.2022.108765

Cited by 17 publications

(6 citation statements)

References 22 publications

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“…The accuracies of the finite-element simulation results and computer time consumption are closely related to the mesh size. Theoretically, the smaller the mesh element size, the more accurate the calculation results will be, but the longer the computer time consumption [ 42 , 43 ]. To balance the contradiction between calculation accuracy and computer time consumption, it is meaningful to select the most suitable mesh element size for finite-element simulation.…”

Section: Finite-element Simulationmentioning

confidence: 99%

Research on Delamination Damage Quantification Detection of CFRP Bending Plate Based on Lamb Wave Mode Control

Yu,

Zhou,

Cheng

et al. 2024

Sensors

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The carbon-fiber-reinforced polymer (CFRP) bending structure is widely used in aviation. The emergence and spread of delamination damage will decrease the safety of in-service bending structures. Lamb waves can effectively identify delamination damage as a high-damage-sensitivity detection tool. For this present study, the signal difference coefficient (SDC) was introduced to quantify delamination damage and evaluate the sensitivity of A0-mode and S0-mode Lamb waves to delamination damage. The simulation results show that compared with the S0-mode Lamb wave, the A0-mode Lamb wave exhibits higher delamination damage sensitivity. The delamination damage can be quantified based on the strong correlation between the SDC and the delamination damage size. The control effect of the linear array PZT phase time-delay method on the Lamb wave mode was investigated by simulation. The phase time-delay method realizes the generation of a single-mode Lamb wave, which can separately excite the A0-mode and S0-mode Lamb wave to identify delamination damage of different sizes. The A0-mode Lamb wave was excited by the developed one-dimensional miniaturized linear comb transducer (LCT), which was used to conduct the detection experiment on the CFRP bending plate with delamination damage sizes of Φ6.0 mm, Φ10.0 mm, and Φ15.0 mm. The experimental results verify the correctness of the simulation. According to the Hermite interpolation results of the finite-element simulation data, the relationship between the delamination damage size and the SDC was fitted by the Gaussian function and Rational function, which can accurately quantify the delamination damage. The absolute error of the delamination damage quantification with Gaussian and Rational fitting expression does not exceed 0.8 mm and 0.7 mm, and the percentage error is not more than 8% and 7%. The detection and signal processing methods employed in the present research are easy to operate and implement, and accurate delamination damage quantification results have been obtained.

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Section: Finite-element Simulationmentioning

confidence: 99%

Research on Delamination Damage Quantification Detection of CFRP Bending Plate Based on Lamb Wave Mode Control

Yu,

Zhou,

Cheng

et al. 2024

Sensors

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“…For the analysis of the stress field, C3D8 cells were used. The DED process involves dynamically injecting metal powder into the molten pool, and the numerical analysis model adopts the “progressive activation element” method to simulate the dynamic generation of the deposition layer [ 27 ].…”

Section: Fem Modelmentioning

confidence: 99%

The Effect of Process Parameters on the Temperature and Stress Fields in Directed Energy Deposition Inconel 690 Alloy

Liu,

Zhan,

Zhao

et al. 2024

Materials

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Additive manufacturing (AM) technology has the advantages of designability, short process times, high flexibility, etc., making it especially suitable for manufacturing complex high-performance components for high-end industrial systems. However, the intensive temperature gradients caused by the rapid heating and cooling processes of AM can generate high levels of residual stresses, which directly affect the precision and serviceability of the components. Taking Inconel 690 alloy, which is widely used in nuclear power plants, as the research object, a thermo-coupled mechanical model of temperature field and residual stress field of directed energy deposition (DED) of Inconel 690 was established based on ABAQUS 2019 finite element software to study the influence of process parameters on the temperature history and the distribution of residual stresses in the DED process. The experimental results show that the peak temperature of each layer in the fabrication process increases with the increase in laser power and preheating temperature, and decreases with the increase in scanning speed and interlayer dwell time. Substrate preheating only has a large effect on the peak temperature of the first four layers. Residual stresses are mainly concentrated in the upper and middle parts, the bottom of the substrate, and the sides combined with the substrate, and the residual stresses increase with the increasing laser power and decrease with the increasing interlayer dwell time. Decreasing laser power, longer dwell time, higher preheating temperature, and appropriate scanning speed are beneficial for the reduction in residual stresses in Inconel 690 components. This research has important significance for the process design and residual stress modulation in the additive manufacturing of Inconel 690 alloy.

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“…The variation of thermophysical parameters of TC4 titanium alloy with temperature was considered [7]. Based on the birth-death element method, a single-channel multi-layer laser cladding model of TC4 titanium alloy plate (0.08 m ൈ 0.08 m ൈ 0.005 m) was established in ABAQUS2020.…”

Section: Numerical Simulationmentioning

confidence: 99%

Finite Element Analysis of Residual Stress in Laser Cladding Remanufacturing of Titanium Alloy

Xie,

Lei,

Wang

et al. 2023

Advances in Transdisciplinary Engineering

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In the process of laser cladding, local heat input causes uneven temperature distribution and then produces thermal stress. The large temperature gradient in the melted-solidified region causes uneven plastic deformation due to solid-liquid phase change. In the study, based on the different types of heat source, the numerical models of single-layer and multi-layer laser cladding on single channel were established in virtue of the transient thermal-mechanical coupling analysis method. The three-dimensional residual stress fields of specific paths were established.

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A novel finite element method for simulating residual stress of TC4 alloy produced by laser additive manufacturing

Cited by 17 publications

References 22 publications

Research on Delamination Damage Quantification Detection of CFRP Bending Plate Based on Lamb Wave Mode Control

Research on Delamination Damage Quantification Detection of CFRP Bending Plate Based on Lamb Wave Mode Control

The Effect of Process Parameters on the Temperature and Stress Fields in Directed Energy Deposition Inconel 690 Alloy

Finite Element Analysis of Residual Stress in Laser Cladding Remanufacturing of Titanium Alloy

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