Abstract
In this research, Wire Arc Additive Manufacturing is modelled and simulated to determine the most suitable bead modelling strategy. This analysis is aimed to predict distortion by means of thermomechanical Finite Element Method (FEM). The product model with wire as feedstock on plate as substrate and process simulation are designed in form of multi-layered beads and single string using MSC Marc/Mentat. This research begins with finding suitable WAAM parameters which takes into account the bead quality. This is done by using robotic welding system with 01.2mm filler wire (AWS A5.28 : ER80SNi1), shielding gas (80% Ar/ 20% CO2) and 6mm-thick low carbon steel as base plate. Further, modelling as well as simulation are to be conducted with regards to bead spreading of each layers. Two different geometrical modelling regarding the weld bead are modelled which are arc and rectangular shape. Equivalent material properties from database and previous researches are implemented into simulation to ensure a realistic resemblance. It is shown that bead modelling with rectangular shape exhibits faster computational time with less error percentage on distortion result compared to arc shape. Moreover, by using the rectangular shape, the element and meshing are much easier to be designed rather than arc shape bead.
Highlights
Wire-arc additive manufacturing (WAAM) can be explained as a modern competitive method of metallic parts fabrication with complicated structure and geometries which based on multi-layer multi-bead (MLMB) parts
By utilizing CMM, the percentage of distortion in certain nodes were calculated, the same nodes pointed in the Finite Element Method (FEM) simulation
There are some crucial points that will be explained by following statements: 1. The FEM analysis of WAAM model were executed successfully and the simulation procedure is clear as well as structured, 2
Summary
Wire-arc additive manufacturing (WAAM) can be explained as a modern competitive method of metallic parts fabrication with complicated structure and geometries which based on multi-layer multi-bead (MLMB) parts. This technology uses electric arc to melt metallic wire and can achieve a high feed rate [1] The WAAM denomination gathers various techniques for metallic parts manufacturing, which can be distinguished by the nature of the energy source allowing the metal deposit or densification, and by the form of the raw material [2]. The production of high-grade alloy components by direct metal deposition shows considerable promise for industrial application in the manufacturing environment. Selective laser melting delivers net shape components with high resolution; to electron beam melting, deposition rates are relatively low, and part size is limited by the enclosed working envelope [5]
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