Dejan Kovšca (Author), Bojan Starman (Author), Damjan Klobčar (Author), Miroslav Halilovič (Author), Nikolaj Mole (Author)

Abstract

In the present work, a comprehensive framework for finite element-based computational modelling of Directed Energy Deposition (DED) process is presented. The proposed approach can be fully automated and implemented on a complex real-life part geometry to accurately predict a thermo-mechanical response during the full-scale deposition process. The discrete material deposition modelling in Finite Element Analysis (FEA) leads to artificial increases in temperature gradients in the melt pool domain. A new method is therefore proposed that aims to mitigate these gradients. Additionally, an easy-to-implement free-surface detection algorithm to accurately prescribe the evolving heat transfer boundary conditions is presented. A three-dimensional sequentially coupled thermo-mechanical model of the process is then validated against experimental data obtained in a deposition case study. The simulation results show good agreement with the in-situ temperature measurements taken during the actual deposition. In addition, result analysis showed that the largest tensile residual stresses form in the hoop and axial direction on the outer domain of the thin-wall cylindrical part near the base plate while the inward material is compressed.

Keywords

directed energy deposition;multi-pass welding;computational modelling;finite element method;thermo-mechanical analysis;

Data

Language: English
Year of publishing:
Typology: 1.01 - Original Scientific Article
Organization: UL FS - Faculty of Mechanical Engineering
UDC: 621.791:519.61
COBISS: 150969347 Link will open in a new window
ISSN: 0168-874X
Views: 145
Downloads: 35
Average score: 0 (0 votes)
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Other data

Secondary language: Slovenian
Secondary keywords: usmerjeno odlaganje energije;večprehodno varjenje;računalniška simulacija;metoda končnih elementov;termomehanska analiza;
Type (COBISS): Article
Pages: str. 1-12
Issue: ǂVol. ǂ221
Chronology: Sept. 2023
DOI: 10.1016/j.finel.2023.103949
ID: 18809965
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