Modeling and convergence analysis of directed energy deposition simulations with hybrid implicit / explicit and implicit solutions

• Autorzy: Buhl Johannes , Israr Rameez , Bambach Markus

Identyfikatory

DOI

10.5604/01.3001.0013.4086

• Języki publikacji: EN

Abstrakty

EN

Conventional metal manufacturing techniques are suitable for mass production. However, cheaper and faster alternatives are preferred for small batch sizes and individualized components. Directed energy deposition (DED) processes allow depositing metallic material in almost arbitrary shapes. They are characterized by cyclic heat input, hence heating and cooling every point in the workpiece several times. This temperature history leads to distribution of mechanical properties, distortions, residual stresses or even fatigue properties in the part. To avoid experimental trial-and-error optimization, different methods are available to simulate DED processes. Currently, the wire arc additive manufacturing (WAAM) is the most competitive DED process. In this work, a simulation method for the WAAM process is established and validated, which should be capable to calculate global effects (e.g. distortions, residual stresses) of real WAAM-processes with duration of hours and thousands of weld beads. The addition of beads and layers is simulated by the element birth and death technique. The elements are activated according to the movements of the heat source (arc). In this paper, the influence of the time step, the mesh size and the material properties of the inactive elements in hybrid implicit / explicit and fully implicit solutions are evaluated with respect to the computation time and stability. This investigation concludes several recommendations for AM-modelling. For example, a low Young’s modulus (100 N/mm²) for the inactive elements show nearly no influences on the welding simulation, but introduces numerical instabilities in case of multiple welding beads. The Young’s modulus should be increased to 1.000 N/mm² for small mesh-sizes, small step-sizes and many beads, even when it introduces unwanted stresses.

Słowa kluczowe

EN

additive manufacturing; steel; implicit/explicit; thermal cycles

• Wydawca: Wydawnictwo Wrocławskiej Rady FSNT NOT
• Czasopismo: Journal of Machine Engineering
• Rocznik: 2019
• Tom: Vol. 19, No. 3
• Strony: 94--107
• Opis fizyczny: Bibliogr. 34 poz., rys., tab.

Twórcy

autor

Buhl Johannes

• Brandenburg University of Technology Cottbus–Senftenberg, Dept. of Mechanical Design and Manufacturing, Cottbus, Germany

autor

Israr Rameez

• Brandenburg University of Technology Cottbus–Senftenberg, Dept. of Mechanical Design and Manufacturing, Cottbus, Germany

autor

Bambach Markus

• Brandenburg University of Technology Cottbus–Senftenberg, Dept. of Mechanical Design and Manufacturing, Cottbus, Germany

Bibliografia

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Uwagi

Opracowanie rekordu w ramach umowy 509/P-DUN/2018 ze środków MNiSW przeznaczonych na działalność upowszechniającą naukę (2019).