Finite element modeling of multi-pass welding and shaped metal deposition processes

Chiumenti, Michele; Cervera, Miguel; Salmi, Alessandro; Saracibar, C. Agelet de; Dialami, Narges; Matsui, Kazumi

doi:10.1016/j.cma.2010.02.018

Cited by 199 publications

(115 citation statements)

References 24 publications

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“…This power redistribution preserves the total energy input independently of the mesh used (see (Chiumenti et al 2010)). …”

Section: Remarkmentioning

confidence: 99%

“…At each time-step a number of elements (activated elements) are switched on according to the powder deposition along the scanning sequence de…ned by the user. Only active and activated elements are assembled into the solution model (see also (Chiumenti et al 2010)). …”

Section: Fe Modeling Of the Am Processmentioning

confidence: 99%

“…Many researchers have used the FE method to study additive manufacturing technologies, often taking advantage from the experience acquired in modeling welding processes (Aggarangsi et al 2003), (Labudovic et al 2003), (Jendrzejewski et al 2004), (Jendrzejewski et al 2007), (Zekovic (Yang et al 2010), (Chiumenti et al 2010), (Anca et al 2011), (Marimuthu et al 2013), (Denlinger et al 2014), (Kelly et al 2014) and (Heigel et al 2015).…”

mentioning

confidence: 99%

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Numerical simulation and experimental calibration of additive manufacturing by blown powder technology. Part I: thermal analysis

Chiumenti

Lin

Cervera

et al. 2017

RPJ

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106

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Purpose This paper aims to address the numerical simulation of additive manufacturing (AM) processes. The numerical results are compared with the experimental campaign carried out at State Key Laboratory of Solidification Processing laboratories, where a laser solid forming machine, also referred to as laser engineered net shaping, is used to fabricate metal parts directly from computer-aided design models. Ti-6Al-4V metal powder is injected into the molten pool created by a focused, high-energy laser beam and a layer of added material is sinterized according to the laser scanning pattern specified by the user. Design/methodology/approach The numerical model adopts an apropos finite element (FE) activation technology, which reproduces the same scanning pattern set for the numerical control system of the AM machine. This consists of a complex sequence of polylines, used to define the contour of the component, and hatches patterns to fill the inner section. The full sequence is given through the common layer interface format, a standard format for different manufacturing processes such as rapid prototyping, shape metal deposition or machining processes, among others. The result is a layer-by-layer metal deposition which can be used to build-up complex structures for components such as turbine blades, aircraft stiffeners, cooling systems or medical implants, among others. Findings Ad hoc FE framework for the numerical simulation of the AM process by metal deposition is introduced. Description of the calibration procedure adopted is presented. Originality/value The objectives of this paper are twofold: firstly, this work is intended to calibrate the software for the numerical simulation of the AM process, to achieve high accuracy. Secondly, the sensitivity of the numerical model to the process parameters and modeling data is analyzed.

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“…This power redistribution preserves the total energy input independently of the mesh used (see (Chiumenti et al 2010)). …”

Section: Remarkmentioning

confidence: 99%

Section: Fe Modeling Of the Am Processmentioning

confidence: 99%

mentioning

confidence: 99%

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Numerical simulation and experimental calibration of additive manufacturing by blown powder technology. Part I: thermal analysis

Chiumenti

Lin

Cervera

et al. 2017

RPJ

Self Cite

106

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“…The proposed strategy is energy conserving (see [29]) provided that (a) the amount of heat generated by friction and plastic dissipation outside the HAZ can be neglected, and (b) the temperature variation due to heat conduction on the inflow and lateral boundaries of the local model during the welding operation is negligible.…”

Section: Local Level Analysismentioning

confidence: 99%

Local–global strategy for the prediction of residual stresses in FSW processes

Dialami

Cervera

Chiumenti

et al. 2016

Int J Adv Manuf Technol

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The final publication is available at Springer via http://dx.doi.org/10.1007/s00170-016-9016-3This work describes the local–global strategy proposed for the computation of residual stresses in friction stir welding (FSW) processes. A coupling strategy between the analysis of the process zone nearby the pin tool (local level analysis) and the simulation carried out for the entire structure to be welded (global level analysis) is implemented to accurately predict the temperature histories and, thereby, the residual stresses in FSW. As a first step, the local problem solves the material stirring as well as the heat generation induced by the pin and shoulder rotation at the heat affected zone. The Arbitrary Lagrangian Eulerian (ALE) formulation is adopted to deal with the rotation of complex pin shapes. A thermo-rigid-viscoplastic constitutive law is employed to characterize the viscous flow of the material, driven by the high-strain rates induced by the FSW process. A mixed temperature–velocity–pressure finite element technology is used to deal with the isochoric nature of the strains. The output of this local analysis is the heat generated either by plastic dissipation or by friction, and it is used as the power input for the welding analysis at structural (global) level. The global problem is tackled within the Lagrangian framework together with a thermo-elasto-viscoplastic constitutive model. In addition, in this case, the mixed temperature–displacement–pressure format is introduced to deal with the deviatoric nature of the plastic strains. The outcomes of this analysis are the distortions and the residual stresses after welding. The material used in this work is stainless steel 304 L; however, the methodology presented is applicable to a wide range of materials. The proposed numerical strategy is validated by the experimental evidence.Peer ReviewedPostprint (author's final draft

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“…Recently, vision-sensing systems have been designed to on-line monitor and control the robotic arc welding process to deposit the desired geometry [19][20][21]. Several other organizations throughout the world continue to work in this exciting field of arcwelding-based AM [22][23][24][25][26][27].…”

Section: Introductionmentioning

confidence: 99%

Towards an automated robotic arc-welding-based additive manufacturing system from CAD to finished part

Ding

Shen

Pan

et al. 2016

Computer-Aided Design

158

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Finite element modeling of multi-pass welding and shaped metal deposition processes

Cited by 199 publications

References 24 publications

Numerical simulation and experimental calibration of additive manufacturing by blown powder technology. Part I: thermal analysis

Numerical simulation and experimental calibration of additive manufacturing by blown powder technology. Part I: thermal analysis

Local–global strategy for the prediction of residual stresses in FSW processes

Towards an automated robotic arc-welding-based additive manufacturing system from CAD to finished part

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