Toward large-scale simulation of residual stress and distortion in wire and arc additive manufacturing
Abstract
In this study, we aim to advance the structural analysis of wire and arc additive manufacturing (WAAM) by considering the thermomechanical features inherent in direct energy deposition. Simulation approaches including the iterative substructure method (ISM), dynamic mesh refining method (DMRM), and graphics processing unit (GPU) based explicit finite element method (FEM) were developed for accelerating additive manufacturing stress analysis that is very time consuming by conventional numerical methods. ISM and DMRM take advantage of the strong nonlinearity phenomenon near the moving heat source by reducing the global iterations and refining the local mesh, respectively. In addition to the use of GPUs, the explicit FEM is accelerated by a time scaling technique based on the inherent strain concept. The residual stress and distortion of two large builds were analyzed, showing very consistent numerical results and good agreement with experiments. Compared with the commercial software Abaqus, the novel approaches reduced the computational cost substantially without compromising accuracy. The GPU code showed the highest computational efficiency (30~70×), while DMRM and ISM had acceleration factors of 9× and 3×, respectively. Finally, such high-fidelity modeling approaches will be very useful for building up a digital twin of WAAM to reduce development time and cost.
- Authors:
-
[1];
[1];
[1];
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Osaka Univ. (Japan)
- Publication Date:
- Research Org.:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Org.:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V)
- OSTI Identifier:
- 1617817
- Alternate Identifier(s):
- OSTI ID: 1616359
- Grant/Contract Number:
- AC05-00OR22725
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Additive Manufacturing
- Additional Journal Information:
- Journal Volume: 34; Journal Issue: C; Journal ID: ISSN 2214-8604
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; 42 ENGINEERING; Wire and arc additive manufacturing; Adaptive mesh; Substructure; Explicit FEM; GPU
Citation Formats
Huang, Hui, Ma, Ninshu, Chen, Jian, Feng, Zhili, and Murakawa, Hidekazu. Toward large-scale simulation of residual stress and distortion in wire and arc additive manufacturing. United States: N. p., 2020.
Web. doi:10.1016/j.addma.2020.101248.
Huang, Hui, Ma, Ninshu, Chen, Jian, Feng, Zhili, & Murakawa, Hidekazu. Toward large-scale simulation of residual stress and distortion in wire and arc additive manufacturing. United States. https://doi.org/10.1016/j.addma.2020.101248
Huang, Hui, Ma, Ninshu, Chen, Jian, Feng, Zhili, and Murakawa, Hidekazu. Thu .
"Toward large-scale simulation of residual stress and distortion in wire and arc additive manufacturing". United States. https://doi.org/10.1016/j.addma.2020.101248. https://www.osti.gov/servlets/purl/1617817.
@article{osti_1617817,
title = {Toward large-scale simulation of residual stress and distortion in wire and arc additive manufacturing},
author = {Huang, Hui and Ma, Ninshu and Chen, Jian and Feng, Zhili and Murakawa, Hidekazu},
abstractNote = {In this study, we aim to advance the structural analysis of wire and arc additive manufacturing (WAAM) by considering the thermomechanical features inherent in direct energy deposition. Simulation approaches including the iterative substructure method (ISM), dynamic mesh refining method (DMRM), and graphics processing unit (GPU) based explicit finite element method (FEM) were developed for accelerating additive manufacturing stress analysis that is very time consuming by conventional numerical methods. ISM and DMRM take advantage of the strong nonlinearity phenomenon near the moving heat source by reducing the global iterations and refining the local mesh, respectively. In addition to the use of GPUs, the explicit FEM is accelerated by a time scaling technique based on the inherent strain concept. The residual stress and distortion of two large builds were analyzed, showing very consistent numerical results and good agreement with experiments. Compared with the commercial software Abaqus, the novel approaches reduced the computational cost substantially without compromising accuracy. The GPU code showed the highest computational efficiency (30~70×), while DMRM and ISM had acceleration factors of 9× and 3×, respectively. Finally, such high-fidelity modeling approaches will be very useful for building up a digital twin of WAAM to reduce development time and cost.},
doi = {10.1016/j.addma.2020.101248},
journal = {Additive Manufacturing},
number = C,
volume = 34,
place = {United States},
year = {Thu Apr 23 00:00:00 EDT 2020},
month = {Thu Apr 23 00:00:00 EDT 2020}
}
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