Advanced computational modelling of metallic wire-arc additive manufacturing

Dejan Kovšca (Author), Bojan Starman (Author), Aljaž Ščetinec (Author), Damjan Klobčar (Author), Nikolaj Mole (Author)

Abstract

Wire-arc welding-based additive manufacturing (WAAM) is a 3D printing technology for production of near-net-shape parts with complex geometry. This printing technology enables to build up a required shape layer by layer with a deposition of a consumable welding wire, where the welding arc is a source of heat. Welding is usually performed by CNC-controlled robotic manipulator, which provides a controlled location of material layer adding. Because the process itself involves thermo-mechanically complex phenomena, Finite Element-based virtual models are commonly employed to optimize the process parameters. This paper presents advanced computational modelling of the WAAM of a tube. A thermo-mechanical numerical model of the process is calibrated against experimental data, measured as temperature variation at the acquisition point. The virtual modelling starts with a preparation of the tube geometry in CAD software, where the geometry of the single-layer cross-section is assumed. The geometry is then exported to a G-code format data file and used to control robotic manipulator motion. On the other side, the code serves as an input to in-house developed code for automatic FEs activation in the simulation of the material layer-adding process. The time of activation of the finite elements (FEs) is directly related to the material deposition rate. The activation of the FEs is followed by a heat source, modeled with a double ellipsoidal power density distribution. The thermo-mechanical problem was solved as uncoupled to speed-up computation.

Keywords

oblikovno obločno navarjanje z žico;večkratno navarjanje;računalniška simulacija;termo-mehanski numerični model;wire-arc additive manufacturing;multi-pass welding;computer simulation;thermo-mechanical numerical model;finite element method;

Data

Language:	English
Year of publishing:	2021
Typology:	1.08 - Published Scientific Conference Contribution
Organization:	UL FS - Faculty of Mechanical Engineering
UDC:	004.942:621.9.04(045)
COBISS:	63316227
Views:	460
Downloads:	119
Average score:	0 (0 votes)
Metadata:

Other data

Secondary language:	English
Secondary keywords:	oblikovno obločno navarjanje z žico;večkratno navarjanje;računalniška simulacija;termo-mehanski numerični model;
Pages:	Str. 1-11
DOI:	10.25518/esaform21.2340
ID:	12863806