Simulative prediction of the manufacturing process in wire-arc additive manufacturing (WAAM) (T03#)

电弧增材制造 (WAAM) 制造过程的模拟预测 (T03

• 批准号: 470693600
• 金额: --
• 依托单位: Institut für Schweißtechnik und Fügetechnik (ISF)
• 依托单位国家: 德国
• 项目类别: Collaborative Research Centres (Transfer Project)
• 财政年份: 2022
• 资助国家: 德国
• 起止时间: 2021-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/470693600?language=en
• 关键词: Simulative; prediction; manufacturing; process; wire

Additive manufacturing holds enormous potential for the future development of the metal processing industry. In particular, the modification of low-cost semi-finished products by individualized structures expands the manufacturing possibilities and increases flexibility and cost-effectiveness in small series. In the field of welding technology research, the development of GMAW process variants for additive manufacturing is currently being increasingly considered (WAAM - wire arc additive manufacturing). This makes it possible to produce metallic components with different topologies directly from the molten metal. It implies that the topology of the substrate is determined during the process by the process itself. A key to the efficient development of an additive manufacturing chain is therefore the availability of mathematical models that enable digital precalculation of the necessary process steps. In particular, this requires a physics-based numerical model of the welding process used. Approaches to this already exist in the field of joint welding, but have not yet been transferred to the additive manufacturing of structures. This will be done in the proposed transfer project with a novel approach, which is expected to solve the numerical problem with reasonable computational effort in the future. In SFB1120, the relationship between molten pool flows during gas metal arc welding and the resulting weld geometry is being researched. So far, the hydrodynamic equations of the molten pool flows have mainly been solved using the Euler approach, where the computational mesh discretizes the entire space of the simulation domain. This approach is particularly well suited for the numerical study of the physical effects of conventional GMA welding, where a linear motion of the torch on a flat plate can be assumed. However, this approach encounters limitations with the dynamic growth of the component geometry, as is the case in the WAAM process. The level-set or VOF methods used in the Euler approach also require the discretization of the entire space, which results in inefficiencies in terms of computational effort, especially for complex component geometries, even when using adaptive meshing strategies. This is contrasted with the SPH approach (smoothed particle hydrodynamics), in which only the considered mass of the material is discretized rather than the entire space of the simulation domain. In order to verify the applicability of the SPH method to the simulation of the MSG welding process, a case study was initiated as an accompaning project within the SFB1120 to confirm transferability to the MSG process. The project described here enables the transfer of the methods, which have so far been used exclusively in the field of basic research, to the field of industrially relevant application-oriented models.

添加剂制造具有巨大的潜力，即金属加工行业的未来发展。特别是，通过个性化结构对低成本半成品产品的修饰扩大了制造可能性，并提高了小型系列的灵活性和成本效益。在焊接技术研究的领域中，目前正在考虑为增材制造的GMAW工艺变体的开发（WAAM-线弧添加剂制造）。这使得可以直接从熔融金属中产生具有不同拓扑的金属成分。这意味着底物的拓扑由过程本身确定。因此，增材制造链有效开发的关键是数学模型的可用性，该模型能够对必要的过程步骤进行数字预测。特别是，这需要基于物理的焊接过程的数值模型。解决方案的方法已经存在于关节焊接领域，但尚未转移到结构的添加剂制造中。这将在拟议的转移项目中采用一种新颖的方法来完成，该方法有望通过未来合理的计算工作来解决数值问题。在SFB1120中，正在研究气体金属弧焊过程中熔融池流与所得的焊接几何形状之间的关系。到目前为止，熔融池流的流体动力方程主要是使用Euler方法求解的，其中计算网格分散了模拟域的整个空间。这种方法特别适合对常规GMA焊接物理效应的数值研究，在这种情况下，可以假定火炬在平板上的线性运动。但是，这种方法与组件几何形状的动态增长相遇，就像WAAM过程中一样。 Euler方法中使用的级别或VOF方法也需要整个空间的离散化，这在计算工作方面会导致效率低下，尤其是对于复杂的组件几何形状，即使使用自适应的网状策略也是如此。这与SPH方法（平滑的粒子流体动力学）形成鲜明对比，其中仅考虑该材料的质量是离散的，而不是模拟域的整个空间。为了验证SPH方法在仿真焊接过程中的适用性，启动了一个案例研究，作为SFB1120中的随附项目，以确认转移到MSG过程中。此处描述的项目使这些方法的转移迄今已在基础研究领域仅用于工业相关的以应用程序为导向的模型。