Geometric distortion-compensation via transient numerical simulation for directed energy deposition additive manufacturing

Biegler, Max; Elsner, B.; Graf, Benjamin; Rethmeier, Michael

doi:10.1080/13621718.2020.1743927

Cited by 30 publications

(9 citation statements)

References 16 publications

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“…7 Metallographic analysis of 2-mm-thick substrates for longitudinal (0°/0°) and transversal (90°/90°) scanning strategies conditions. For the distortion prediction of more complex geometries, FEA-based thermo-mechanical models as applied for example by Biegler et al [20] should be considered. For further experimental analysis of in situ cantilever distortion, displacement could be measured by displacement sensors rather than a video camera and temperature by sensors that cover the full expected temperature range.…”

Section: Effect Of Scanning Strategiesmentioning

confidence: 99%

“…Xie et al [19] developed a numerical model with layer-by-layer element activation and found that computational time could be reduced by a factor of greater than 10 compared to conventional step-to-step element activation. Biegler et al [20] analyzed shape deviations during the fabrication of a turbine blade consisting of 80 layers using the commercial software Simufact Welding. They showed that the application of the simulation results for distortion compensation could increase the geometrical accuracy of the final part.…”

Section: Introductionmentioning

confidence: 99%

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Effect of clad height, substrate thickness and scanning pattern on cantilever distortion in direct metal deposition

Soffel

Eisenbarth

Wegener

2021

Int J Adv Manuf Technol

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In metal additive manufacturing, moving heat sources cause spatial and time-dependent variations of temperature and strain that can lead to part distortions. Distortion prediction and optimized deposition parameters can increase the dimensional accuracy of the generated components. In this study, an analytical approach for modeling the effect of clad height and substrate thickness is experimentally validated. Additionally, the influence of the scanning pattern as a function of clad height and substrate thickness is determined experimentally. The analytical model is based on the cool-down phase mechanism and assumes the formation of constant thermal shrinking forces for each deposited layer. The model accurately predicts longitudinal cantilever distortion after experimental calibration when compared with similar experimental conditions. For multi-layer deposition, the scanning pattern has the largest influence on distortion for thin-walled substrates. An optimized deposition strategy with longitudinal scanning vectors leads to a distortion reduction of up to 86%. The results highlight the potential of mechanical modeling and scanning strategy optimizations to increase the shape accuracy for industrial applications in the field of additive manufacturing.

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Section: Effect Of Scanning Strategiesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effect of clad height, substrate thickness and scanning pattern on cantilever distortion in direct metal deposition

Soffel

Eisenbarth

Wegener

2021

Int J Adv Manuf Technol

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“…They concluded that the thermo-mechanical model combined with the stress-relaxation model yielded more accurate results, as compared to a conventional thermo-mechanical model for LDED. Biegler et al [9][10][11] validated the thermo-mechanical model for SS 316Lwith in situ DIC results at the deposited part (simple walls and curved shape). They demonstrated an approach to accurately predict distortions for industrial-scale LDED parts.…”

Section: Introductionmentioning

confidence: 99%

Conventional Meso-Scale and Time-Efficient Sub-Track-Scale Thermomechanical Model for Directed Energy Deposition

et al. 2022

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Thermally-induced distortion and residual stresses in parts fabricated by the additive manufacturing (AM) process can lead to part rejection and failure. Still, the understanding of thermo–mechanical behavior induced due to the process physics in AM process is a complex task that depends upon process and material parameters. In this work, a 3D thermo-elasto-plastic model is proposed to predict the thermo–mechanical behavior (thermal and distortion field) in the laser-directed energy deposition (LDED) process using the finite element method (FEM). The predicted thermo–mechanical responses are compared to stainless steel 316L (SS 316L) deposition, with single and double bead 42-layer wall samples subject to different inter-layer dwell times, which govern the thermal response of deposited parts in LDED. In this work, the inter-layer dwell times used in experiments vary from 0 to 10 s. Based on past research into the LDED process, it is assumed that fusion and thermal cycle-induced annealing leads to stress relaxation in the material, and is accounted for in the model by instantaneously removing stresses beyond an inversely calibrated relaxation temperature. The model predicts that, for SS 316L, an increase in dwell time leads to a decrease in in situ and post-process distortion values. Moreover, increasing the number of beads leads to an increase in in situ and post-process distortion values. The calibrated numerical model’s predictions are accurate when compared with in situ and post-process experimental measurements. Finally, an elongated ellipsoid heat source model is proposed to speed up the simulation.

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“…They found that by increasing the preheating temperature it is possible to minimize part distortion and residual stresses. Recently, some researches introduced geometric compensation as an effective strategy to counterbalance the part distortions induced by the thermal field in AM [26][27][28].…”

Section: Introductionmentioning

confidence: 99%

Warpage Analysis and Control of Thin-Walled Structures Manufactured by Laser Powder Bed Fusion

Chiumenti

Cervera

et al. 2021

Metals

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Thin-walled structures are of great interest because of their use as lightweight components in aeronautical and aerospace engineering. The fabrication of these components by additive manufacturing (AM) often produces undesired warpage because of the thermal stresses induced by the manufacturing process and the components’ reduced structural stiffness. The objective of this study is to analyze the distortion of several thin-walled components fabricated by Laser Powder Bed Fusion (LPBF). Experiments are performed to investigate the sensitivity of the warpage of thin-walled structures fabricated by LPBF to different design parameters such as the wall thickness and the component height in several open and closed shapes. A 3D-scanner is used to measure the residual distortions in terms of the out-of-plane displacement. Moreover, an in-house finite element software is firstly calibrated and then used to enhance the original design in order to minimize the warpage induced by the LPBF printing process. The outcome of this shows that open geometries are more prone to warping than closed ones, as well as how vertical stiffeners can mitigate component warpage by increasing stiffness.

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Geometric distortion-compensation via transient numerical simulation for directed energy deposition additive manufacturing

Cited by 30 publications

References 16 publications

Effect of clad height, substrate thickness and scanning pattern on cantilever distortion in direct metal deposition

Effect of clad height, substrate thickness and scanning pattern on cantilever distortion in direct metal deposition

Conventional Meso-Scale and Time-Efficient Sub-Track-Scale Thermomechanical Model for Directed Energy Deposition

Warpage Analysis and Control of Thin-Walled Structures Manufactured by Laser Powder Bed Fusion

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