Three-dimensional finite element modelling for additive manufacturing of Ti-6Al-4V components: Effect of scanning strategies on temperature history and residual stress

Zhou, Jinbiao; Barrett, Richard A.; Leen, Seán B.

doi:10.1016/j.jajp.2022.100106

Cited by 20 publications

(12 citation statements)

References 66 publications

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“…Although the present component-level modelling method uses some simplifications (e.g. coarse mesh and large step increment), which may affect the predicted thermal history and cooling rate, 30 it enables computationally-efficient component-level analysis of the distribution of residual stresses in the printed components without sacrificing accuracy.…”

Section: Discussionmentioning

confidence: 99%

“…The FE analysis is performed using Abaqus/CAE 2020. 38 The bridge-shaped geometry built on a cuboid substrate, modelled here using the ‘Abaqus AM’ method, of which more details can be found in our previous paper, 30 is based on that experimentally examined by Phan et al, 11 as shown in Figure 3. The dimensions of the printed component are 75 mm ( L ) × 5 mm ( W ) × 12.5 mm ( H ).…”

Section: Methodsmentioning

confidence: 99%

“…610 MPa, as compared to 440 MPa). In our previous work, 30 a 3D FE model using Abaqus AM was developed to predict thermal histories and residual stresses in a realistic DED Ti-6Al-4V component.…”

Section: Introductionmentioning

confidence: 99%

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Finite element modelling for mitigation of residual stress and distortion in macro-scale powder bed fusion components

Zhou

Barrett

Leen

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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Powder bed fusion (PBF) has attracted significant attention in many applications due to its capability of fabricating complex and customized metal parts. However, the potential for high inherent residual stresses that produce distortion in additive manufacturing (AM) components prevents more widespread application of the AM technique. Efficient and accurate prediction of residual stress and distortion at component-level (macro-scale) is a complex task. Although process-level (meso-scale) thermo-mechanical simulations have resulted in accurate predictions for small-scale parts, the computational times (typically weeks) and memory requirements for application of such methods to component-level are prohibitive. The main goal of the current study therefore is to present an efficient and accurate finite element (FE) simulation method with detailed validation for PBF manufacture of a complex 3D Inconel 625 benchmark bridge component (macro-scale). The simulation results are successfully validated against the published benchmark experimental measurements from neutron diffraction, X-ray diffraction (XRD), contour method and coordinate measurement machine (CMM) by the National Institute of Standards and Technology (NIST) laboratory. A key additional novelty of the present work is the investigation of the effects of substrate removal and preheating on mitigation of residual stresses and distortions using the validated model. Ultimately, these results will guide the selection of optimal manufacturing protocols and integration of the FE-based AM modelling for industrial application with complex geometries. The ultimate aim of the present work is to facilitate fatigue life prediction of complex geometry AM components including residual stress effects, for example, conformally-cooled injection moulding dies (for different material than Inconel 625).

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Section: Discussionmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

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Finite element modelling for mitigation of residual stress and distortion in macro-scale powder bed fusion components

Zhou

Barrett

Leen

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

Self Cite

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“…Microstructure and, consequently, mechanical characteristics and residual stresses, as required for precise evaluation and planning for structural stability, such as fatigue cracking, are of particular concern in the current work, and thus the need for objects based on such realistic configurations of thermal records is of particular importance. The new model 33 exhibits considerably better cooling rate agreement, a crucial factor in phase transition prediction, making modelling of complicated engineering components more practical. By incorporating the familiar Goodman formula for the impact of mean stress to Basquin's equation 33 , we obtain the relationship between fatigue life N f and stress range, mean stress, and residual stress as given in Equation ( 4).…”

Section: Approaches Concerning Theoretical Prediction Of Residual Str...mentioning

confidence: 99%

A Review on Thermal Modelling of Residual Stresses during Additive Manufacturing

N. Chethan Kumar,

Jhavar

2023

jmmf

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Additive Manufacturing (AM) has received interest since it is simpler to manufacture complicated 3D component without the requirement for casting moulds than convective fabrication. AM has a lot of significance in fields like aerospace, medicine, and more to make parts of any kind of complex shape. Since the finished products are subjected to repeated cycles of heating and cooling, there will always be some residual stresses present in them. During layer-over-layer deposition, the large difference in temperature between the layers causes residual stresses, which hurt the performance of the products. As far as the author’s knowledge, there is no thorough review of the thermal modelling of residual stress in AM. In this review paper, the goal is to first get a good understanding of how residual stresses are developed, and then to look at how different models measure them. So, residual stresses can be seen as a key factor in controlling costs, performance, and quality standards of the finished component. This paper does a thorough review of the field to give engineers and researchers up-to-date information and advice about residual stresses.

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“…Many researchers have studied the effects of different paths on the temperature and stress fields. Zhou et al [24] analyzed the temperature field and stress field by studying different paths in multilayer single-pass. Zhao et al [25] studied the evolution of thermal stresses and the effect of residual stresses in a multilayer single-pass additive process.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Investigation of CMT Wire and Arc Additive Manufacturing of 2205 Duplex Stainless Steel

Yuan

et al. 2022

Coatings

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In this paper, the mechanical properties, microhardness and metallographic structure of 2205 duplex stainless steel by cold metal transfer (CMT) wire and arc additive manufacturing process are studied. The results show that the ultimate tensile strength, yield strength and elongation at break of reciprocating additive along building direction (BD) are 856.73 MPa, 710.5 MPa and 42.35%, respectively. In addition, the same direction motion (SDM) and reciprocating motion (RM) is selected as parameter variables in the experiment, and the finite element model is established by ABAQUS software, and the temperature and residual stress field of the additive forming at different paths are tested and simulated. Firstly, the accuracy of the selected finite element model was verified by comparing the experimental results from the simulation results to the macroscopic morphology of the cross-section of the single-pass additive specimen. The numerical simulation results show that due to the difference of the additive scanning paths, the distribution of the temperature field has a large difference, and with the increase of the deposited layer, the heat accumulation of the SDM additive is larger than that of the RM, so that the end collapses of the SDM additive will occur in the actual additive specimen. By simulating and comparing the equivalent stress distribution of different paths, the equivalent stress distribution of SDM and RM is approximately the same in the vertical direction, and the minimum of equivalent stress appears at the bottom of the deposition layers, about 116.5 MPa, and the maximum of equivalent stress appears at 8 mm from the top, about 348 MPa.

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Three-dimensional finite element modelling for additive manufacturing of Ti-6Al-4V components: Effect of scanning strategies on temperature history and residual stress

Cited by 20 publications

References 66 publications

Finite element modelling for mitigation of residual stress and distortion in macro-scale powder bed fusion components

Finite element modelling for mitigation of residual stress and distortion in macro-scale powder bed fusion components

A Review on Thermal Modelling of Residual Stresses during Additive Manufacturing

Experimental and Numerical Investigation of CMT Wire and Arc Additive Manufacturing of 2205 Duplex Stainless Steel

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