Sensitivity analysis and lattice density optimization for sequential inherent strain method used in additive manufacturing process

Takezawa, Akihiro; To, Albert C.; Chen, Qian; Liang, Xuan; Dugast, Florian; Zhang, Xiaopeng; Kitamura, Mitsuru

doi:10.1016/j.cma.2020.113231

Cited by 40 publications

(5 citation statements)

References 49 publications

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“…Actually, the process of welding or AM is far more complicated than the proposed Bar-frame model, for instance, phase transformation [12] and work hardening [63] should both be considered in welding and AM. The case is more complicated for AM as the remelting of the previous layers and the surrounding material when scanning the next layer or pass should be considered [32], moreover, the constraint condition for the whole model is altering all the time due to its layer-by-layer building characteristic [27][28][29]. However, the Bar-frame model can shed some light on the routes designed for reducing residual stress induced in these thermal-related process.…”

Section: |mentioning

confidence: 99%

“…Many researches have been done to control and reduce residual stresses in additive manufacturing (AM) [26][27][28][29][30][31][32]. Preheating the substrate is a commonly used in-situ method [24].…”

Section: Introductionmentioning

confidence: 99%

“…Later in late 80s, Mura [50] described this inelastic strain as "eigenstrain", he presented that eigenstrain is any kind of permanent strain due to inelastic process such as plastic deformation, crystallographic transformation, thermal expansion mismatch between different parts of assembly which causes incompatibility in the material, leading to the occurrence of residual stress distribution. In recent years, inherent strain theory has also been applied to analyze metal AM processes as they share similar characteristics with metal welding processes in which the materials will experience a cycle of heating and cooling and left with inherent strains [20,28,29,31,32,51,52]. In the AM built parts and heat-affected zone of welding pass, when the metal cools down to ambient temperature, there will be in-plane compressive inherent strains (usually inherent strain equals to plastic strain in this case if phase transformation is not considered) left, which are formed due to the constraint of the surrounding area during contraction.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Laser shock forging—a novel in situ method designed towards controlling residual stresses in laser metal deposition

Zhang

Cai

Yang

et al. 2023

Int J Adv Manuf Technol

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This paper presents a novel hybrid in-situ additive manufacturing (AM) method -Laser Shock Forging (LSF), which combines laser shock peening (LSP) with laser melting deposition (LMD). Based on the classical Bar-frame model and inherent strain theory, the mechanisms of the effects of pretreatment and post-treatment on AM process has been rstly elaborated. Towards controlling tensile residual stress (TRS) in the as-built (AB) state of AM parts which has a detrimental effect on their fatigue life, we then developed LSF to introduce tensile inherent strains in LMD built parts in an in-situ manner, which will convert TRS to compressive residual stress (CRS). The laser beam used for shock peening can be adjusted to move synchronously with the laser beam used for metal deposition at a certain distance, ensuring the laser shock peening to act on the region where the material temperature cools down to the forging temperature range. Then experimental works have been conducted on 316L stainless steel, residual stress distributions of the AB, LSP and LSF treated specimens were compared, results show that LSF increases both the magnitude and depth of CRS compared with conventional LSP treatment, thus providing a promising application in enhancing fatigue life in AM process.

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Section: |mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Laser shock forging—a novel in situ method designed towards controlling residual stresses in laser metal deposition

Zhang

Cai

Yang

et al. 2023

Int J Adv Manuf Technol

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“…Since antiquity, human beings have learned to create tools, the act of creating is what makes possible a process that determines a product (BI et al, 2017). Over time came the need to evolve, and with that Industrial Revolution emerged, which allowed the involvement of numerous experiments and case studies that enabled researchers to new methods of optimization in manufacturing processes (Ćwiklicki et al, 2020;Takezawa et al, 2020).…”

Section: Contextualization Of Manufacturing Processesmentioning

confidence: 99%

Digital technologies review for manufacturing processes

Parente

Silva

Siqueira

et al. 2022

Ind. Jour. Manag. & Prod.

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It is apparent the industrial processes transformations caused by industry 4.0 are in advance in some countries like China, Japan, Germany and United States. But, in return, the developing countries, as the emergent Brazil, seem like to have a long way to achieve digital era. Considering manufacturing processes as the starting point the rise of industry 4.0, this research aims to show a review about the most important technologies used in smart manufacturing, including the main challenges to implement it at Brazil. The papers were collected from Web of Science (WoS), comprising 114 articles and 2 books to underpin this study. This exploratory research resulted in the presentation of some challenges faced by Brazilian industry to join the new industrial era, such as poor technological infrastructure, besides lack of investment in technologies and training of qualified people. Even though the primary motivation of this research was to present a panorama of smart manufacturing for Brazil, this study results contributes to the most of emergent countries, bringing together general concepts and addressing practical applications developed by several researchers from the international academic community.

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“…23–25 Another advantage of the AM lattice structure is the variable lattice shape and performance according to the location-dependent functionally graded material. 26–30 Such an approach was also applied to the stem, whereby design optimization was performed through a minimization of the bone loss and interface failure due to stress shielding and the strength requirement constraints. 31–33 Another example is optimal stem design with an objective function that brings the mean stress of the residual bone close to the mean stress of the pure bone.…”

Section: Introductionmentioning

confidence: 99%

Design optimization of functionally graded lattice infill total hip arthroplasty stem for stress shielding reduction

Nomura

Takezawa

Zhang

et al. 2022

Proc Inst Mech Eng H

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Reducing stress shielding of stem-inserted femurs in total hip arthroplasty caused by the high stiffness of the stem is an emerging medical engineering issue. In this study, a numerical design optimization methodology lattice infill stem was developed to realize a stem, balancing the low stiffness and strength requirements. Two pairs of models and loading conditions were introduced for the stress shielding and strength criteria. The objective function was set as the weighted sum of the criteria. Its effective density distribution was optimized by handling the representative size of the lattice as a design variable, assuming that the so-called body-centered cubic lattice was the base shape of the lattice. In the optimization, the approximated model of the lattice was handled as a solid material with the effective physical properties of the lattice derived by the homogenization method. After optimization, the detailed lattice stem geometry was modeled based on the obtained optimal lattice distribution, and the actual performance was numerically evaluated. The developed stem increased the stress applied to the remaining femur by 32.4% compared with the conventional stem.

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Sensitivity analysis and lattice density optimization for sequential inherent strain method used in additive manufacturing process

Cited by 40 publications

References 49 publications

Laser shock forging—a novel in situ method designed towards controlling residual stresses in laser metal deposition

Laser shock forging—a novel in situ method designed towards controlling residual stresses in laser metal deposition

Digital technologies review for manufacturing processes

Design optimization of functionally graded lattice infill total hip arthroplasty stem for stress shielding reduction

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