Advanced computational modelling of metallic wire-arc additive manufacturing

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

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.

• Language: Slovenian
• Keywords: wire-arc additive manufacturing, multi-pass welding, computer simulation, thermo-mechanical numerical model, finite element method
• Typology: 1.08 - Published Scientific Conference Contribution
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Publication date: 28.03.2021
• Year: 2021
• Number of pages: Str. 1-11
• Numbering: art. 2340
• PID: 20.500.12556/RUL-126860
• UDC: 004.942:621.9.04(045)
• DOI: 10.25518/esaform21.2340
• COBISS.SI-ID: 63316227
• Publication date in RUL: 06.05.2021

Record is a part of a monograph

• Title: 24th International Conference on Material Forming, Liège, Belgium, 14 - 16 April, 2021 : ESAFORM 2021
• Editors: Anne Marie Habraken
• Place of publishing: Liège
• Publisher: AIM
• Year: 2021
• COBISS.SI-ID: 62587395

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.
• Licensing start date: 29.03.2021

Secondary language

• Language: English
• Keywords: oblikovno obločno navarjanje z žico, večkratno navarjanje, računalniška simulacija, termo-mehanski numerični model

Projects

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