A computationally efficient finite element model of wire and arc additive manufacture
A computationally efficient finite element model of wire and arc additive manufacture
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DOI：
10.1007/s00170-013-5261-x
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发表时间：
2014-01-01
影响因子：
3.4
通讯作者：
Almeida, P. Sequeira
中科院分区：
文献类型：
--
作者：
Ding, J.;Colegrove, P.;Almeida, P. Sequeira
线弧增材制造（WAAM）是一种新兴技术，通过以高沉积速率生产近净形部件，有可能显著减少材料使用量和制造时间。该工艺的主要问题之一是沉积工件的残余应力和变形。为了帮助理解和优化该过程，通常使用有限元（FE）模型;然而，传统的瞬态模型对于模拟大规模WAAM过程并不有效。本文利用瞬态热机械有限元模型研究了WAAM工艺热循环过程中的应力演化。结果发现，在WAAM工艺的热循环过程中经历的峰值温度决定了该点的残余应力。基于这一发现，一个有效的“工程”有限元模型的开发。与传统的瞬态热力学方法相比，该模型可以节省99%的计算时间。这个新的模型产生的变形和残余应力的预测是几乎相同的原始瞬态模型和实验结果。
Wire and arc additive manufacturing (WAAM) is an emerging technology which has the potential to significantly reduce material usage and manufacturing time through the production of near net-shape components with high deposition rates. One of the main problems of this process is the residual stresses and distortions of the deposited workpiece. To help understand and optimise the process, finite element (FE) models are commonly used; however, the conventional transient models are not efficient for simulating a large-scale WAAM process. In this paper, the stress evolution during the thermal cycles of the WAAM process was investigated with the help of a transient thermomechanical FE model. It was found that the peak temperatures experienced during the thermal cycles of the WAAM process determine the residual stress of that point. Based on this finding, an efficient "engineering" FE model was developed. Compared to the conventional transient thermomechanical approach, this model can save the computational time by 99 %. This new model produced distortion and residual stress predictions that were nearly identical to the original transient model and the experimental results.