Speaker
Description
Additive manufacturing using wire arc technology, especially Cold Metal Transfer
(CMT), has become increasingly popular in the generation of large-scale and complex
shaped 3D parts. However, heat input and solidification shrinkage during deposition
causes distortions and residual stresses. These can significantly affect the geometric
accuracy and mechanical properties of the deposit. Process simulation offers the
possibility to predict the evolution of such stresses and distortions numerically.
Possible violations of geometric tolerances and high stress concentrations can be
identified in advance. Expensive trial-and-error can be reduced or eliminated.
This study deals with the numerical modeling of residual stresses and distortions
occurring during additive manufacturing of Al-5083 parts with weaving deposition.
The effects of various modeling parameters on the simulation results including
clamping forces, heat source geometry and mesh size will be investigated.
Furthermore, the impact of an accurate implementation of the heat source weaving
pattern will be elaborated. The mechanical material properties for the simulation are
evaluated utilizing in-house standardized test equipment. Validation of the thermomechanical simulation is done by monitoring temperatures and distortions during the
process. Additionally, 3D scans of the part geometry and residual stress measurements
using the hole drilling method are conducted post manufacturing.
This study shows the capability of the numerical prediction of residual stresses and
distortions for wire arc additive manufacturing processes. The results provide useful
insight on the importance of certain input parameters to calibrate the thermomechanical simulation model.
| Speaker Country | Österreich |
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