Numerical Simulation Development and Computational Optimization for Directed Energy Deposition Additive Manufacturing Process
Numerical Simulation Development and Computational Optimization for Directed Energy Deposition Additive Manufacturing Process
复制标题
定向能量沉积增材制造过程数值模拟与计算优化
DOI：
10.3390/ma13112666
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发表时间：
2020-06-01
期刊：
影响因子：
3.4
通讯作者：
Dzugan, Jan
中科院分区：
文献类型：
--
作者：
Kiran, Abhilash;Hodek, Josef;Dzugan, Jan
增材制造（AM）在过去十年中的快速增长已经证明了具有上级质量产品的成本效益生产的巨大潜力。数值模拟是了解和改进产品质量、生命周期和生产成本的一种陡峭的方式。为了科普日益增长的增材制造领域，研究人员正在探索不同的技术，方法，模型来有效地模拟增材制造过程。目的是开发一个热机械焊接模型的定向能量沉积（DED）过程中的316 L不锈钢在一个有效的计算成本，针对大型AM零件的残余应力计算模型。为了使焊接模型适应DED模拟，进行了单轨道和多轨道热模拟。数值计算结果通过DED实验得到验证。数值模拟预测的温度趋势与实验结果吻合较好。三维实体增材制造零件中存在大量的焊接轨迹，这使得有限元过程模拟在计算时间和大量数据管理方面具有挑战性。采用逐层激活元素并以循环方式引入热量的方法，称为热循环热输入。热循环热输入大大减少了计算时间。将数值结果与热应力和残余应力分析的实验数据进行比较。为了进一步减少计算时间，采用了层集总策略。分析了不同集总层数对残余应力计算精度的影响。用等截面切割法对沉积试样的分层残余应力计算进行了验证。研究了不同集总层数的热行为和残余应力预测，并报告了计算时间减少。
The rapid growth of Additive Manufacturing (AM) in the past decade has demonstrated a significant potential in cost-effective production with a superior quality product. A numerical simulation is a steep way to learn and improve the product quality, life cycle, and production cost. To cope with the growing AM field, researchers are exploring different techniques, methods, models to simulate the AM process efficiently. The goal is to develop a thermo-mechanical weld model for the Directed Energy Deposition (DED) process for 316L stainless steel at an efficient computational cost targeting to model large AM parts in residual stress calculation. To adapt the weld model to the DED simulation, single and multi-track thermal simulations were carried out. Numerical results were validated by the DED experiment. A good agreement was found between predicted temperature trends for numerical simulation and experimental results. A large number of weld tracks in the 3D solid AM parts make the finite element process simulation challenging in terms of computational time and large amounts of data management. The method of activating elements layer by layer and introducing heat in a cyclic manner called a thermal cycle heat input was applied. Thermal cycle heat input reduces the computational time considerably. The numerical results were compared to the experimental data for thermal and residual stress analyses. A lumping of layers strategy was implemented to reduce further computational time. The different number of lumping layers was analyzed to define the limit of lumping to retain accuracy in the residual stress calculation. The lumped layers residual stress calculation was validated by the contour cut method in the deposited sample. Thermal behavior and residual stress prediction for the different numbers of a lumped layer were examined and reported computational time reduction.