Numerical analysis of hardness variations for a dome built without supports using directed energy deposition and multi-axis tool paths

There are many process parameters for directed energy deposition (DED) that influence product quality. Using a well-defined analytical model to simulate the process increases the knowledge of the process. In this paper, a finite element analysis of hardness and temperature history for a thin-wall he...

Full description

Saved in:
Bibliographic Details
Published in:International journal of advanced manufacturing technology 2021-09, Vol.116 (3-4), p.975-991
Main Authors: Kalami, Hamed, Urbanic, Jill
Format: Article
Language:English
Subjects:
Beads
CAE) and Design
Computer-Aided Engineering (CAD
Deposition
Diameters
Domes
Engineering
Finite element analysis
Finite element method
Hardness
Industrial and Production Engineering
Mechanical Engineering
Media Management
Metallurgy
Numerical analysis
Original Article
Process parameters
Substrates
Citations: Items that this one cites
Online Access:Get full text
Tags: Add Tag
No Tags, Be the first to tag this record!
Description
Summary:There are many process parameters for directed energy deposition (DED) that influence product quality. Using a well-defined analytical model to simulate the process increases the knowledge of the process. In this paper, a finite element analysis of hardness and temperature history for a thin-wall hemisphere dome is investigated using the SYSWELD software. The dome diameter and thickness are 45 mm and 2 mm respectively, and 144 beads of varying lengths is required to fabricate this part without support structures. A three-dimensional thermo-metallurgical-mechanical solution is used to generate the hardness. Two approaches for heat input are applied: constant laser efficiency and constant melt pool size. The results show a reasonable match between the experimental hardness data and the finite element analysis. The numerical results correlated better for the base segments than for those built at the top. Influence factors vary as the component is built, as conduction into the substrate occurs for the base partitions, but convection and radiation influence the heat losses at the top for thin-walled components. This illustrates the challenges with respect to developing accurate results. Faster numerical analysis techniques need to be developed to simulate products fabricated by DED additive manufacturing processes.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-021-07504-6