Towards an automated framework for the finite element computational modelling of directed energy deposition

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

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.

• Language: English
• Keywords: directed energy deposition, multi-pass welding, computational modelling, finite element method, thermo-mechanical analysis
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2023
• Number of pages: 12 str.
• Numbering: Vol. 221, art. 103949
• PID: 20.500.12556/RUL-145657
• UDC: 621.791:519.61
• ISSN on article: 0168-874X
• DOI: 10.1016/j.finel.2023.103949
• COBISS.SI-ID: 150969347
• Publication date in RUL: 05.05.2023

Record is a part of a journal

• Title: Finite elements in analysis and design
• Shortened title: Finite elem. anal. des.
• Publisher: Elsevier
• ISSN: 0168-874X
• COBISS.SI-ID: 579602

Licences

• License: CC BY-NC-ND 4.0, Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International
• Link: http://creativecommons.org/licenses/by-nc-nd/4.0/
• Description: The most restrictive Creative Commons license. This only allows people to download and share the work for no commercial gain and for no other purposes.

Secondary language

• Language: Slovenian
• Keywords: usmerjeno odlaganje energije, večprehodno varjenje, računalniška simulacija, metoda končnih elementov, termomehanska analiza

Projects

• Funder: ARRS - Slovenian Research Agency
• Project number: P2-0263
• Name: Mehanika v tehniki

• Funder: ARRS - Slovenian Research Agency
• Project number: L2-3172
• Name: Razvoj tehničnih smernic za štirislojne zasteklitve