Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Grilli, Nicolò; Hu, Daijun; Yushu, Dewen; Fan, Caimei; Yan, Wentao

doi:10.1007/s00466-021-02116-z

Cited by 22 publications

(5 citation statements)

References 79 publications

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“…The authors concluded that the developed method could predict deformation with an error of no more than 26%. A plasticity model for modeling the formation of residual stresses and evaluating the correlation between plastic deformation, grain orientation, and residual stresses in the additive manufacturing process was developed by Grilli et al [44]. The wide possibilities of the finite element method for modeling the shaping process and optimizing process parameters are presented in a study by Zhang with colleagues [45].…”

Section: Methods For the Determination Of Plasticity Marginmentioning

confidence: 99%

Plasticity Resource of Cast Iron at Deforming Broaching

Nemyrovskyi

Shepelenko

Storchak

2023

Metals

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The contact interaction mechanics of deformation broaching in low-plasticity materials is studied. Particular attention is paid to the study of the stress–strain state parameters and the plasticity margin in the deformation zone during the machining of gray cast iron EN-GJL-200. The stress–strain state was analyzed using a finite-element model of the deforming broaching process for each area of the deformation zone. The model parameters of the machined material were determined experimentally by compressing specimens of gray cast iron EN-GJL-200. The changes in the parameters of accumulated strain, stress tensor components, stress triaxiality ratio, hydrostatic stress, and plasticity margin at different deformation zones along the machined specimen depth are analyzed. It is shown that there is a zone of local plastic deformation in conditions of critical contact stresses. This leads to the appearance of tensile stresses that reduce the plasticity margin in the surface layer. The impact of tool geometry on the stress–strain state of the surface layer is also discussed, and recommendations for the optimal working angle of the deforming element are provided based on plasticity margin minimization.

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Section: Methods For the Determination Of Plasticity Marginmentioning

confidence: 99%

Plasticity Resource of Cast Iron at Deforming Broaching

Nemyrovskyi

Shepelenko

Storchak

2023

Metals

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“…[ 234 ] Relations between plastic deformation, grain orientation, and formation of RS are also studied. [ 235 ] The volume change caused by austenite–martensite transition and the resultant RS is investigated for the traditional welding process [ 236 ] and DED‐based repair process. [ 237 ] However, such discussion has still been lacking for AM, in which complex solid phase transformations and intermetallic phase formation are prevailing due to the far‐from‐equilibrium solidification nature.…”

Section: Challenges and Opportunitiesmentioning

confidence: 99%

Evolution, Control, and Mitigation of Residual Stresses in Additively Manufactured Metallic Materials: A Review

Liu,

Shi,

Wang

2023

Adv Eng Mater

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Powder bed fusion (PBF) and directed energy deposition (DED) are the two major types of metal additive manufacturing (AM) processes, in which significant residual stresses could be generated in the as‐deposited materials and in turn affect part quality and performance. Therefore, how to control and mitigate residual stress has been a most pressing challenge for metal AM. In this paper, we systematically review the significant efforts made in literature to address this challenge for both PBF and DED processes. The extensive survey covers the formation of residual stress in AM, influence of various AM process parameters, modeling techniques for predicting residual stresses, and post and in‐situ treatments for mitigating unfavorable residual stress distributions. More importantly, a critical analysis is provided to discuss the research gaps and opportunities, such that more exciting research will be stimulated to address the outstanding issues in this area, and improve the quality and service life of AM produced components. As a result, once being better equipped with residual stress control knowledge and tools, the industry will be more confident in adopting metal AM techniques.This article is protected by copyright. All rights reserved.

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“…The thermal and mechanical problems presented by FGMs are very complicated because the gradient layers are heterogeneous both microscopically and macroscopically. Because of the large temperature gradients and high-frequency heating-cooling cycles during the LAM process, it is di cult to monitor the temperature and thermal stress in real time during experiments [25]. In order to verify the correctness of this model, a TC4 alloy model of the same size is established with the same method, and the result graph calculated by the commonly used "Model Change" method is provided, showing the difference between the two methods.…”

Section: Models Veri Cationmentioning

confidence: 99%

Residual stress analysis of TC4/Inconel718 functionally graded material produced by laser additive manufacturing based on progressive activation element method

Zhao,

Gao,

Wang

et al. 2023

Int J Adv Manuf Technol

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With the continuous development of preparation technology, laser additive manufacturing (LAM) has become one of the effective ways to manufacture functionally graded materials due to its unique layerby-layer stacking technology. However, the repeated and repeated rapid heating and cooling processes in the manufacturing process will generate large residual stress inside the structure, resulting in the destruction of the structure. In this paper, based on a new nite element method called progressive activation element method (PAE), a thermomechanical coupling model for simulating the process of LAM is established, and the in uence of laser power and composition ratio of transition layers on the residual stress of the overall structure is discussed. The results show that there is a positive correlation between the laser power and the residual stress. The PAE method is compared with the traditional "Model Change" method, and it is found that the PAE method has advantages in computational e ciency, especially when calculating the residual stress of functionally graded materials, the e ciency can be improved by about 1650%. When the TC4/Inconel718 functionally graded material is prepared experimentally, the optimal composition ratio of the transition layers is 8:2. This paper provides reference for the understanding and reasonable suppression of residual stress of functionally graded materials in LAM.

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Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Cited by 22 publications

References 79 publications

Plasticity Resource of Cast Iron at Deforming Broaching

Plasticity Resource of Cast Iron at Deforming Broaching

Evolution, Control, and Mitigation of Residual Stresses in Additively Manufactured Metallic Materials: A Review

Residual stress analysis of TC4/Inconel718 functionally graded material produced by laser additive manufacturing based on progressive activation element method

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