Incremental inherent stress model for the fast prediction of part distortion made via wire arc additive manufacturing
| dc.rights.license | open | en_US |
| hal.structure.identifier | ESTIA - Institute of technology [ESTIA] | |
| dc.contributor.author | POULHAON, Fabien | |
| dc.contributor.author | SPRINGER, Sebastian | |
| dc.contributor.author | GRUBER, Thomas | |
| dc.contributor.author | LASNIK, Michael | |
| dc.contributor.author | OBERWINKLER, Bernd | |
| hal.structure.identifier | ESTIA - Institute of technology [ESTIA] | |
| dc.contributor.author | JOYOT, Pierre
ORCID: 0000-0002-6608-7343 IDREF: 085496057 | |
| dc.date.accessioned | 2025-02-14T08:21:42Z | |
| dc.date.available | 2025-02-14T08:21:42Z | |
| dc.date.issued | 2024-07-15 | |
| dc.identifier.issn | 1526-6125 | en_US |
| dc.identifier.uri | https://oskar-bordeaux.fr/handle/20.500.12278/204859 | |
| dc.description.abstractEn | Additive manufacturing, particularly Wire Arc Additive Manufacturing (WAAM), provides numerous advantages for the production of near net shape components, since it combines a high productivity with a reduced material waste. It is of major interest when working with expensive materials such as titanium alloy Ti-6Al-4V, commonly used in aerospace. Due to high temperature gradients WAAM is very susceptible to high residual stresses and hence, distortion problems. In order to avoid extensive experimental parameter studies in the design phase to mitigate these issues, a process design based on numerical simulation is favourable. However, accurate estimations up to now necessitate the implementation of transient multi-physics models, which may not be effective when applied to large structures because of their associated large computational time. Consequently, there is a clear need for faster numerical models, especially when path planning optimization is targeted. A promising very fast approach to solve this problem is the so-called inherent strain formulation. However, the original inherent strain formulation is hard to implement in certain commercial finite element (FE) software packages, since strain data is harder to access than stress data. In addition, the original approach requires the modification of the FE solver itself, and hence needs to be adapted for each FE analysis software package individually, which is not only inefficient but might lead also to different results. To overcome these issues a more universally applicable and non-intrusive incremental Inherent Stress formulation that can be incorporated to any commercial finite element solver has been developed within this work. Within the modelling approach the additive manufacturing of a representative component is simulated bead by bead, with the addition of each new bead corresponding to a linear elastic problem that can be rapidly solved. Furthermore, the model incorporates the temperature dependency of the Young's modulus during heating and cooling cycles to better account for thermo-mechanical coupling. Evolution of inherent stress during the deposition of successive layers is also introduced to increase the fidelity of the model. The validity of the model was assessed using two stiffened representative geometries with different complexity. In both cases, a major reduction in computational up to 98 % is observed, with a corresponding displacement error of 20 % in the worst-case scenario, thus constituting an interesting tool to evaluate distortion trends. | |
| dc.language.iso | EN | en_US |
| dc.title | Incremental inherent stress model for the fast prediction of part distortion made via wire arc additive manufacturing | |
| dc.type | Article de revue | en_US |
| dc.identifier.doi | 10.1016/j.jmapro.2024.05.034 | en_US |
| dc.subject.hal | Sciences de l'ingénieur [physics] | en_US |
| bordeaux.journal | Journal of Manufacturing Processes | en_US |
| bordeaux.page | 136-149 | en_US |
| bordeaux.volume | 121 | en_US |
| bordeaux.hal.laboratories | ESTIA - Recherche | en_US |
| bordeaux.institution | Université de Bordeaux | en_US |
| bordeaux.peerReviewed | oui | en_US |
| bordeaux.inpress | non | en_US |
| bordeaux.import.source | crossref | |
| hal.identifier | hal-04947229 | |
| hal.version | 1 | |
| hal.date.transferred | 2025-02-14T08:21:45Z | |
| hal.popular | non | en_US |
| hal.audience | Internationale | en_US |
| hal.export | true | |
| workflow.import.source | crossref | |
| dc.rights.cc | Pas de Licence CC | en_US |
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