Multi-bead overlapping model with varying cross-section profile for robotic GMAW-based additive manufacturing

Hu, Zeqi; Qin, Xunpeng; Li, Yifeng; Yuan, Jiuxin; Wu, Qiang

doi:10.1007/s10845-019-01501-z

Cited by 57 publications

(7 citation statements)

References 31 publications

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“…Another type of additive manufacturing process uses raw material in the form of wire and electric arc as a source of energy for melting. This process is also called as Wire Arc additive manufacturing process and commonly uses Gas Tungsten Arc Welding (GTAW) (Wang et al, 2004;Xiong et al, 2019), Gas Metal Arc Welding (GMAW) (Gonz alez et al, 2017;Hu et al, 2020) and Plasma Arc welding (Lin et al, 2017;Artaza et al, 2020) as an energy source for melting. The wire arc additive manufacturing is emerging as a competing solution for the manufacturing of metallic components because of its low investment cost.…”

Section: Introductionmentioning

confidence: 99%

Development of a deposition framework for implementation of a region-based adaptive slicing strategy in arc-based metal additive manufacturing

Gokhale

Kala

2021

RPJ

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Purpose This study aims to develop and demonstrate a deposition framework for the implementation of a region-based adaptive slicing strategy for the Tungsten Inert Gas (TIG) welding-based additive manufacturing system. The present study demonstrates a deposition framework for implementing a novel region-based adaptive slicing strategy termed as Fast Interior and Accurate Exterior with Constant Layer Height (FIAECLH). Design/methodology/approach The mentioned framework has been developed by performing experiments using the design of experiments and analyzing the experimental data. Analysis results have been used to obtain the mathematical function to integrate customization in the process. The paper, in the end, demonstrates the FIAECLH framework for implementing region-based adaptive slicing strategy on the hardware level. Findings The study showcase a new way of implementing the region-based adaptive slicing strategy to arc-based metal additive manufacturing. The study articulating a new strategy for its implementation in all types of wire and arc additive manufacturing processes. Originality/value Wire-arc-based technology has the potential to deliver cost-effective solutions for metal additive manufacturing. The research on arc welding-based processes is being carried out in different dimensions. To deposit parts with complex geometry and better dimensional accuracy implementation of a novel region-based adaptive slicing strategy for the arc-based additive manufacturing process is an essential task. The successful implementation of an adaptive slicing strategy would ease the fabrication of complex geometry in less time. This paper accomplishes this need of implementing a region-based adaptive slicing strategy as no experimental investigation has been reported for the TIG-based additive manufacturing process.

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Section: Introductionmentioning

confidence: 99%

Development of a deposition framework for implementation of a region-based adaptive slicing strategy in arc-based metal additive manufacturing

Gokhale

Kala

2021

RPJ

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“…Principally, WAAM comprises a combination of heating source from electric arc with a feeding system of metallic wire which enables the component production layerby-layer through building strategy by means of welding technology such as gas metal arc welding (GMAW). In many research outcomes, metal component produced by WAAM can reach the tensile strength of casting or forging part [14][15][16].…”

Section: Introductionmentioning

confidence: 99%

Experimental validation of numerical simulation on deformation behaviour induced by wire arc additive manufacturing with feedstock SS316L on substrate S235

Ahmad

Manurung

Adenan

et al. 2021

Int J Adv Manuf Technol

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This fundamental research aims to analyse the effect of heat transfer coefficients, plasticity model of evolved material properties and simplified meshing strategy on substrate deformation induced by wire arc additive manufacturing (WAAM) process with dissimilar materials based on experiment and numerical simulation. Throughout the experiment, stainless steel wire SS316L was used as feedstock to build a five-layer and three-string component on an 8-mm-thick low carbon steel S235 as substrate plate by means of a robotic GMAW system with pure argon as shielding gas and diagonal clamping. In order to define heat transfer coefficients by adjusting simulation to experimental results, the transient thermal distribution was to be measured at specific points located in the component layer using Type K thermocouple inserted during the process and on the substrate implanted beforehand. For modelling and simulation, a non-linear thermo-mechanical method was applied in which the component was modelled using rectangular element shape with optimized hexagonal mesh size obtained through sensitivity analysis in accordance to actual specimen geometry and clamping condition. Non-linear isotropic hardening rule with von Mises yield criterion and temperature-dependent material properties was implemented into the simulation which were generated by means of advanced material modelling software based on elemental composition of evolved component characterized using SEM/EDX. For numerical and experimental validation purpose, substrate deformation was measured using coordinate measurement machine before and after the process. It can be concluded that the result of the computed substrate deformation showed an acceptable agreement compared to experiment within the range of error between 0.5 and 27.5% at each specific measurement points and 10.1% as average single error. This basic investigation can be enhanced in the case where cost-effective WAAM application with dissimilar materials towards single-piece substrate component is concerned.

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“…Various research groups have used numerical computation to investigate the distortion induced by the WAAM process. The effect of the cooling time applied in the deposition of layers during the WAAM process was analysed, leading to the conclusion that FEM is capable of optimizing the final deformation result within an acceptable error percentage (Panda et al , 2016; Hu et al , 2019). Another distortion analysis of the WAAM process using numerical computation was conducted and showed that a simulation using simplified bead modelling gave a good agreement with experimental results – within a percentage error of 17.3% – and massively reduced computing time (Prajadhiana et al , 2019).…”

Section: Introductionmentioning

confidence: 99%

Experimental verification of computational and sensitivity analysis on substrate deformation and plastic strain induced by hollow thin-walled WAAM structure

Prajadhiana

Manurung

Bauer

et al. 2021

RPJ

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Purpose This paper aims to numerical and experimental analysis on substrate deformation and plastic strain induced by wire arc additive manufacturing. Design/methodology/approach The component has the form of a hollow, rectangular thin wall consisting of 25 deposition layers of SS316L on an SS304 substrate plate. Thermo-mechanical finite element analysis was applied with Goldak’s double-ellipsoidal heat-source model and a non-linear isotropic hardening rule based on von Mises’ yield criterion. The layer deposition was modelled using simplified geometry to minimize overall pre-processing work and computational time. Findings A new material modelling of SS316L was obtained from the chemical composition of the evolved component characterized by scanning electron microscope/energy dispersive X-ray and further generated by an advanced material-modelling software JMatPro. In defining heat-transfer coefficients, transient thermometric analysis was first performed in the bead and on the substrate, which was followed by an adjustment of the heat-transfer coefficients to reflect the actual temperature distribution. Based on the adjusted model and boundary conditions, sensitivity analysis was conducted prior to the ultimate simulation of substrate deformation and equivalent plastic strain. Furthermore, this simulation was verified by conducting a series of automated wire + arc additive manufacturing tests using robotic gas Metal arc welding with distortion measured by coordinate-measurement machine and equivalent plastic strain measured by optical three-dimensional-metrology measurements (Gesellschaft für Optische Messtechnik). Originality/value It can be concluded that a proper numerical computation using the adjusted model and property-evolved material exhibits a similar trend with acceptable agreement compared to the experiment by yielding an error percentage up to 30% for deformation and up to 21% for equivalent plastic strain at each individual measurement point.

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Multi-bead overlapping model with varying cross-section profile for robotic GMAW-based additive manufacturing

Cited by 57 publications

References 31 publications

Development of a deposition framework for implementation of a region-based adaptive slicing strategy in arc-based metal additive manufacturing

Development of a deposition framework for implementation of a region-based adaptive slicing strategy in arc-based metal additive manufacturing

Experimental validation of numerical simulation on deformation behaviour induced by wire arc additive manufacturing with feedstock SS316L on substrate S235

Experimental verification of computational and sensitivity analysis on substrate deformation and plastic strain induced by hollow thin-walled WAAM structure

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