Finite element analysis of in-situ distortion and bulging for an arbitrarily curved additive manufacturing directed energy deposition geometry

dc.contributor.authorBiegler, Max
dc.contributor.authorMarko, Angelina
dc.contributor.authorGraf, Benjamin
dc.contributor.authorRethmeier, Michael
dc.date.accessioned2020-09-15T15:33:57Z
dc.date.available2020-09-15T15:33:57Z
dc.date.issued2018-10-05
dc.description.abstractWith the recent rise in the demand for additive manufacturing (AM), the need for reliable simulation tools to support experimental efforts grows steadily. Computational welding mechanics approaches can simulate the AM processes but are generally not validated for AM-specific effects originating from multiple heating and cooling cycles. To increase confidence in the outcomes and to use numerical simulation reliably, the result quality needs to be validated against experiments for in-situ and post-process cases. In this article, a validation is demonstrated for a structural thermomechanical simulation model on an arbitrarily curved Directed Energy Deposition (DED) part: at first, the validity of the heat input is ensured and subsequently, the model’s predictive quality for in-situ deformation and the bulging behaviour is investigated. For the in-situ deformations, 3D-Digital Image Correlation measurements are conducted that quantify periodic expansion and shrinkage as they occur. The results show a strong dependency of the local stiffness of the surrounding geometry. The numerical simulation model is set up in accordance with the experiment and can reproduce the measured 3-dimensional in-situ displacements. Furthermore, the deformations due to removal from the substrate are quantified via 3D-scanning, exhibiting considerable distortions due to stress relaxation. Finally, the prediction of the deformed shape is discussed in regards to bulging simulation: to improve the accuracy of the calculated final shape, a novel extension of the model relying on the modified stiffness of inactive upper layers is proposed and the experimentally observed bulging could be reproduced in the finite element model.en
dc.identifier.issn2214-8604
dc.identifier.urihttps://depositonce.tu-berlin.de/handle/11303/11666
dc.identifier.urihttp://dx.doi.org/10.14279/depositonce-10554
dc.language.isoenen
dc.rights.urihttp://rightsstatements.org/vocab/InC/1.0/en
dc.subject.ddc620 Ingenieurwissenschaften und zugeordnete Tätigkeitende
dc.subject.otherDEDen
dc.subject.otherwelding simulationen
dc.subject.otheradditive manufacturingen
dc.subject.otherdimensional accuracyen
dc.subject.otherdigital image correlationen
dc.subject.otherDirected Energy Depositionen
dc.titleFinite element analysis of in-situ distortion and bulging for an arbitrarily curved additive manufacturing directed energy deposition geometryen
dc.typeArticleen
dc.type.versionacceptedVersionen
dcterms.bibliographicCitation.doi10.1016/j.addma.2018.10.006en
dcterms.bibliographicCitation.journaltitleAdditive Manufacturingen
dcterms.bibliographicCitation.originalpublishernameElsevieren
dcterms.bibliographicCitation.originalpublisherplaceAmsterdam [u.a.]en
dcterms.bibliographicCitation.pageend272en
dcterms.bibliographicCitation.pagestart264en
dcterms.bibliographicCitation.volume24en
tub.accessrights.dnbfreeen
tub.affiliationFak. 5 Verkehrs- und Maschinensysteme>Inst. Werkzeugmaschinen und Fabrikbetrieb>FG Fügetechnikde
tub.affiliation.facultyFak. 5 Verkehrs- und Maschinensystemede
tub.affiliation.groupFG Fügetechnikde
tub.affiliation.instituteInst. Werkzeugmaschinen und Fabrikbetriebde
tub.publisher.universityorinstitutionTechnische Universität Berlinen
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