Finite Element mesh coarsening for effective distortion prediction in Wire Arc Additive Manufacturing

Montevecchi, Filippo; Venturini, Giuseppe; Grossi, Niccolò; Scippa, Antonio; Campatelli, Gianni

doi:10.1016/j.addma.2017.10.010

Cited by 44 publications

(35 citation statements)

References 39 publications

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“…Previous research found that the substrate and the deposited track have symmetrical distortion when the substrate is not clamped [13,14]. The distortion along the Z-direction is much larger than that along the other two directions [16].…”

Section: Materials and Methodologymentioning

confidence: 99%

“…The captured images revealed that the laser added wall showed a slight U-shape with the middle being bent downward in the Z-direction after cooling. Montevecchi [14] and Yu [15] also found symmetrical distortion of the substrate in WAAM and LMD processes, respectively. Gao’s investigation [16] showed that the distortion of the substrate along the Z-direction was much larger than that along the other two directions (X- and Y-directions) throughout the designed laser scanning patterns.…”

Section: Introductionmentioning

confidence: 97%

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Assumption of Constraining Force to Explain Distortion in Laser Additive Manufacturing

et al. 2018

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Distortion is a common but unrevealed problem in metal additive manufacturing, due to the rapid melting in metallurgy and the intricate thermal-mechanical processes involved. We explain the distortion mechanism and major influencing factors by assumption of constraining force, which is assumed between the added layer and substrate. The constraining force was set to act on the substrate in a static structural finite element analysis (FEA) model. The results were compared with those of a thermal-mechanical FEA model and experiments. The constraining force and the associated static structural FEA showed trends in distortion and stress distribution similar to those shown by thermal-mechanical FEA and experiments. It can be concluded that the constraining force acting on the substrate is a major contributory factor towards the distortion mechanism. The constraining force seems to be primarily related to the material properties, temperature, and cross-sectional area of the added layer.

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Section: Materials and Methodologymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 97%

Assumption of Constraining Force to Explain Distortion in Laser Additive Manufacturing

et al. 2018

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“…Xiong et al [4,5] studied the thermal behavior of cylindrical parts made by WAAM through a finite element thermal simulation of the process. Montevecchi et al [6,7] developed a finite element model based on a mesh coarsening technique in order to reduce the computational cost of the process simulation. In the same perspective, Ding et al [10] proposed a finite element approach based on two models (transient and stationary) in order to investigate the thermomechanical behavior of parts manufactured in WAAM.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Modeling and Validation of Metal Deposition in Wire Arc Additive Manufacturing

Chergui

Béraud

Vignat

et al. 2021

Lecture Notes in Mechanical Engineering

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Wire arc additive manufacturing allows the production of metallic parts by depositing beads of weld metal using arc-welding technologies. This low-cost additive manufacturing technology has the ability to manufacture large-scale parts at a high deposition rate. However, the quality of the obtained parts is greatly affected by the various thermal phenomena present during the manufacturing process. Numerical simulation remains an effective tool for studying such phenomena. In this work, a new finite element technique is proposed in order to model metal deposition in WAAM process. This technique allows to gradually construct the mesh representing the deposited regions along the deposition path. The heat source model proposed by Goldak is adapted and combined with the proposed metal deposition technique taking into account the energy distribution between filler material and the molten pool. The effectiveness of the proposed method is validated by series of experiments, of which an example is detailed in this paper.

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“…Ukar et al [26] show a good agreement between a finite-difference-based thermal model and the measured temperature in laser polishing. More recently, Montevecchi et al [27] and Bayat et al [28] performed similar calculations in a finite element framework, but their investigations included the stress build-up and fluid flow respectively.…”

Section: Introductionmentioning

confidence: 99%

Numerical Investigation into the Effect of Different Parameters on the Geometrical Precision in the Laser-Based Powder Bed Fusion Process Chain

et al. 2020

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Due to the layer-by-layer nature of the process, parts produced by laser-based powder bed fusion (LPBF) have high residual stresses, causing excessive deformations. To avoid this, parts are often post-processed by subjecting them to specially designed heat treatment cycles before or after their removal from the base plate. In order to investigate the effects of the choice of post-processing steps, in this work the entire LPBF process chain is modelled in a commercial software package. The developed model illustrates the possibilities of implementing and tailoring the process chain model for metal additive manufacturing using a general purpose finite element (FE) solver. The provided simplified computational example presents an idealised model to analyse the validity of implementing the LPBF process chain in FE software. The model is used to evaluate the effect of the order of the process chain, the heat treatment temperature and the duration of the heat treatment. The results show that the model is capable of qualitatively capturing the effect of the stress relaxation that occurs during a heat treatment at elevated temperature. Due to its implementation, the model is relatively insensitive to duration and heat treatment temperature, at least as long as it is above the relaxation temperature. Furthermore, the simulations suggest that, when post-processing, it is necessary to perform the stress relaxation before the part is removed from the base plate, in order to avoid a significant increase of the deformation. The paper demonstrates the capability of the simulation tool to evaluate the effects of variations in the process chain steps and highlights its potential usage in directing decision-making for LPBF process chain design.

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Finite Element mesh coarsening for effective distortion prediction in Wire Arc Additive Manufacturing

Cited by 44 publications

References 39 publications

Assumption of Constraining Force to Explain Distortion in Laser Additive Manufacturing

Assumption of Constraining Force to Explain Distortion in Laser Additive Manufacturing

Finite Element Modeling and Validation of Metal Deposition in Wire Arc Additive Manufacturing

Numerical Investigation into the Effect of Different Parameters on the Geometrical Precision in the Laser-Based Powder Bed Fusion Process Chain

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