Abstract:Additive manufacturing (AM), which has only relatively recently emerged as one of the most significant sectors, is currently the subject of a great number of research investigations. In contrast to machining, additive manufacturing (AM) is a process that involves the division of items into very thin layers, followed by the production of these layers by stacking previous layers atop one another. AM has found new application areas because to the decrease in weight as well as other advantages in a variety of indu… Show more
“…The gas metal arc-based directed energy deposition (GMA-DED) process exhibits a very high deposition rate and negligible material waste compared to other forms of metal additive manufacturing (AM) processes (Alfattni, 2022; Lidong and Alexander, 2016; Riensche et al , 2023). However, it experiences high heat input during the deposition of layers and yields significant residual stress (RS) in the component, which can further cause the distortion of the substrate (Özdemir and Korkmaz, 2023; Williams et al , 2016). For investigating the effect of transient temperature distribution on the thermal RS, researchers are using the finite element method (FEM; Liu et al , 2022; Teker et al , 2022).…”
Purpose
Gas metal arc-based directed energy deposition (GMA-DED) process experiences residual stress (RS) developed due to heat accumulation during successive layer deposition as a significant challenge. To address that, monitoring of transient temperature distribution concerning time is a critical input. Finite element analysis (FEA) is considered a decisive engineering tool in quantifying temperature and RS in all manufacturing processes. However, computational time and prediction accuracy has always been a matter of concern for FEA-based prediction of responses in the GMA-DED process. Therefore, this study aims to investigate the effect of finite element mesh variations on the developed RS in the GMA-DED process.
Design/methodology/approach
The variation in the element shape functions, i.e. linear- and quadratic-interpolation elements, has been used to model a single-track 10-layered thin-walled component in Ansys parametric design language. Two cases have been proposed in this study: Case 1 has been meshed with the linear-interpolation elements and Case 2 has been meshed with the combination of linear- and quadratic-interpolation elements. Furthermore, the modelled responses are authenticated with the experimental results measured through the data acquisition system for temperature and RS.
Findings
A good agreement of temperature and RS profile has been observed between predicted and experimental values. Considering similar parameters, Case 1 produced an average error of 4.13%, whereas Case 2 produced an average error of 23.45% in temperature prediction. Besides, comparing the longitudinal stress in the transverse direction for Cases 1 and 2 produced an error of 8.282% and 12.796%, respectively.
Originality/value
To avoid the costly and time-taking experimental approach, the experts have suggested the utilization of numerical methods in the design optimization of engineering problems. The FEA approach, however, is a subtle tool, still, it faces high computational cost and low accuracy based on the choice of selected element technology. This research can serve as a basis for the choice of element technology which can predict better responses in the thermo-mechanical modelling of the GMA-DED process.
“…The gas metal arc-based directed energy deposition (GMA-DED) process exhibits a very high deposition rate and negligible material waste compared to other forms of metal additive manufacturing (AM) processes (Alfattni, 2022; Lidong and Alexander, 2016; Riensche et al , 2023). However, it experiences high heat input during the deposition of layers and yields significant residual stress (RS) in the component, which can further cause the distortion of the substrate (Özdemir and Korkmaz, 2023; Williams et al , 2016). For investigating the effect of transient temperature distribution on the thermal RS, researchers are using the finite element method (FEM; Liu et al , 2022; Teker et al , 2022).…”
Purpose
Gas metal arc-based directed energy deposition (GMA-DED) process experiences residual stress (RS) developed due to heat accumulation during successive layer deposition as a significant challenge. To address that, monitoring of transient temperature distribution concerning time is a critical input. Finite element analysis (FEA) is considered a decisive engineering tool in quantifying temperature and RS in all manufacturing processes. However, computational time and prediction accuracy has always been a matter of concern for FEA-based prediction of responses in the GMA-DED process. Therefore, this study aims to investigate the effect of finite element mesh variations on the developed RS in the GMA-DED process.
Design/methodology/approach
The variation in the element shape functions, i.e. linear- and quadratic-interpolation elements, has been used to model a single-track 10-layered thin-walled component in Ansys parametric design language. Two cases have been proposed in this study: Case 1 has been meshed with the linear-interpolation elements and Case 2 has been meshed with the combination of linear- and quadratic-interpolation elements. Furthermore, the modelled responses are authenticated with the experimental results measured through the data acquisition system for temperature and RS.
Findings
A good agreement of temperature and RS profile has been observed between predicted and experimental values. Considering similar parameters, Case 1 produced an average error of 4.13%, whereas Case 2 produced an average error of 23.45% in temperature prediction. Besides, comparing the longitudinal stress in the transverse direction for Cases 1 and 2 produced an error of 8.282% and 12.796%, respectively.
Originality/value
To avoid the costly and time-taking experimental approach, the experts have suggested the utilization of numerical methods in the design optimization of engineering problems. The FEA approach, however, is a subtle tool, still, it faces high computational cost and low accuracy based on the choice of selected element technology. This research can serve as a basis for the choice of element technology which can predict better responses in the thermo-mechanical modelling of the GMA-DED process.
“…Such complex geometries are mainly realized through additive processes (Korkmaz et al , 2022a). Several terms for complex cellular materials have been used (Özdemir and Korkmaz, 2023), and one of such term is mechanical metamaterials and another is cellular structures or cellular materials (Hedayati et al , 2016). Currently, an increasingly common design approach in additive manufacturing (AM) is associated with using such architecturally complex lattices due to the fact that we reduce material consumption (Alfattni, 2022; Wang and Alexander, 2016).…”
Purpose
Additive manufacturing (AM), a rapidly evolving paradigm, has shown significant advantages over traditional subtractive processing routines by allowing for the custom creation of structural components with enhanced performance. Numerous studies have shown that the technical qualities of AM components are profoundly affected by the discovery of novel metastable substructures in diverse alloys. Therefore, the purpose of this study is to determine the effect of cell structure parameters on its mechanical response.
Design/methodology/approach
Initially, a methodology was suggested for testing porous materials, focusing on static tensile testing. For a qualitative evaluation of the cellular structures produced, computed tomography (CT) was used. Then, the CT scanner was used to analyze a sample and determine its actual relative density, as well as perform a detailed geometric analysis.
Findings
The experimental research demonstrates that the mechanical properties of a cell’s structure are significantly influenced by its shape during formation. It was also determined that using selective laser melting to produce cell structures with a minimum single-cell size of approximately 2 mm would be the most appropriate method.
Research limitations/implications
Further studies of cellular structures for testing their static tensile strength are planned for the future. The study will be carried out for a larger number of samples, taking into account a wider range of cellular structure parameters. An important step will also be the verification of the results of the static tensile test using numerical analysis for the model obtained by CT scanning.
Originality/value
The fabrication of metallic parts with different cellular structures is very important with a selective laser melted machine. However, the determination of cell size and structure with mechanical properties is quiet novel in this current investigation.
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