Numerical 3D simulation of wire deposition process to predict distortion of parts

Oleg Yu Smetannikov,Petr V. Maksimov,Dmitriy N. Trushnikov,Gleb L. Permyakov,Vladimir Ya Belenkiy,Alexander S. Farberov

doi:10.1186/s40759-019-0043-2

Abstract

In the work, on the basis of the analysis of publications, existing approaches to the numerical modeling of additive processes of product formation are shown. The work itself is devoted to the study of the influence of parameters of the process of surfacing wire materials on the formation of residual deformations in parts. A mathematical formulation of the non-stationary thermomechanical problem is presented, and algorithms for solving the problem using the technology of birth and death of finite elements in the ANSYS package are described. Verification of the model created by the finite element was carried out on the basis of data from the experiment on surfacing a multilayer sample. The effect on the level of residual warping of the following process parameters was studied: the exposure time before the next layer was deposited; the motion path of the burner; ambient temperature. It is shown that the change in ambient temperature is the most effective way to reduce the residual distortions of the form.

Highlights

Additive manufacturing (AM) - the process of building three-dimensional (3D) parts based on a digital model by gradually adding thin layers of material
The study of the influence of technological parameters of the process on residual distortion As an object of multivariant analysis of residual deformations, a plate made of aluminum alloy D16 with a weldable 10-layer bar was considered
The dimensions of the plate, the thickness of the layers and the method of attachment are identical to the sample S4

Summary

Introduction

Additive manufacturing (AM) - the process of building three-dimensional (3D) parts based on a digital model by gradually adding thin layers of material. This feature allows you to produce complex or unique parts directly from a digital model without the need to develop expensive tooling or molds, reducing the need for many conventional processing steps (Petrick and Simpson 2013; Wray 2014). When creating products by using methods of AM, large temperature gradients and technological residual stresses arise in the volume of the material, resulting in disruption of the product shape, changes in the mechanical and operational characteristics of the object, and its destruction during manufacturing (King et al 2015; Li et al 2010; Ibiye et al 2011; Parry et al 2015; Wu et al 2014; Baufeld et al 2010; Riedlbauer et al 2012). There are three most commonly used methods for simulating material deposition: «element birth», «quiet element» and «hybrid activation» (Martukanitz et al 2014; Michaleris 2014)

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