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Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with
Keval P Prajadhiana1,2, Thoufeili Taufek1,2, Wan Emri Wan Abdul Rahaman2
1Smart Manufacturing Research Institute, UiTM Shah Alam, Selangor, Malaysia.
3D Printing and Additive Manufacturing
|October 3, 2024
Summary
This study analyzes deformation in wire arc additive manufacturing (WAAM) components after substrate removal. The novel thermomechanical simulation method accurately predicts distortion, achieving high accuracy for thin-walled stainless steel structures.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Computational Mechanics
Background:
- Wire Arc Additive Manufacturing (WAAM) is a key technology for producing large metal components.
- Understanding and predicting deformation in WAAM parts after substrate removal is crucial for quality control.
- Existing methods may not fully capture the complex thermomechanical phenomena involved.
Purpose of the Study:
- To numerically and experimentally analyze the deformation of a hollow, rectangular thin-walled component after substrate removal.
- To develop and validate a thermomechanical finite element model for predicting WAAM-induced distortion.
- To assess the accuracy of a novel distortion analysis method incorporating advanced material properties and substrate removal algorithms.
Main Methods:
- Thermomechanical finite element analysis using Goldak's double ellipsoid heat source model and von-Mises yield criterion.
- Simulation software (Simufact.Welding 2021) with separation and deposition algorithms for substrate removal.
- Advanced material modeling (JMATPRO) based on SS316L chemical composition.
- Experimental verification using robotic GMAW, substrate machining, and 3D laser scanning for distortion measurement.
Main Results:
- The numerical model successfully predicted component deformation after substrate removal.
- Experimental measurements of distortion were compared with simulation results.
- The developed method achieved surface deviation between 0.05 and 2.16 mm.
- Pointwise and average error percentages were within an acceptable range (up to 3%).
Conclusions:
- The novel distortion analysis method using thermomechanical numerical computation is effective for predicting WAAM component deformation.
- Accurate material properties and refined substrate removal algorithms are vital for reliable simulation results.
- The study demonstrates a high degree of accuracy in predicting vertical surface deviation, validating the approach.
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