Fundamental Analysis on substrate distortion induced by Wire Arc Additive Manufacturing using experiment and nonlinear FEM with simplified bead model

  • Authors

    • Keval P Prajadhiana
    • Yupiter HP Manurung
    • Zaidi Minggu
    • Fetisia HS Pengadau
    • Hui Leng Choo
    • Marcel Graf
    • Andre Haelsig
    • Tom-Eric Adams
    • Dendi P Ishak
    https://doi.org/10.14419/ijet.v7i4.36.29379
  • WAAM, FEM, Bead Model, Distortion, Isotropic Hardening

  • In this fundamental research, Wire Arc Additive Manufacturing (WAAM) was investigated experimentally with regard to process parameter, bead quality and bead model development. A series of experiment was conducted by using robotic welding system ABB IRB 2400/16 and KEMMPI Pro Evolution ProMIG 540MXE  with Æ1.2mm  filler wire (AWS A5.28 : ER80S-Ni1) and shielding gas (80% AR/ 20% CO2) on 6mm-thick substrate of Low Carbon Steel S235. Based on the experimental result, WAAM geometry is modelled using simplified bead shape following rectangular form under consideration of diluted material. The simulation was carried out by utilizing thermo-mechanical Finite Element Method (FEM) under consideration of non-linear isotropic hardening using commercial FEM software MSC Marc/Mentat. The plasticity model of Low carbon steel and high strength steel also considered under material properties option featured in software database. As comparison, similar material properties from previous researches were implemented into simulation to ensure a realistic resemblance. The analysis of substrate distortion is carried out by utilizing the coordinate measurement machine (CMM) pointed on various locations of substrate with 10 layers and 1 string WAAM. Based on the results between experiment and simulation, it is found out that FEM result with simplified bead model and equivalent plasticity model exhibits a good agreement which falls under the acceptable range of error.

     

     

  • References

    1. [1] Yong ZL, Yunfei S, Qinglin H, Guanjung Z,Imre H, “Enhanced beads overlapping model for wired arc additive manufacturing of multi-layered bead metallic partsâ€, Journals of Material Processing Tech, Vol 252 (2018), pp:838-484.

      [2] F. Wang, S. Williams, M. Rush, “Morphology investigation on direct current pulsed gas tungsten arc welded additive layer manufactured Ti6A14V Alloyâ€. International Journal Advanced Manufacturing Technology, Vol 57 (2011), pp:597-603.

      [3] J. Xiong, R. Li, H. Chem, “Heat propagation of circular thin-walled parts fabricated in additive manufacturing using gas metal arc weldingâ€. Journal of Material Processing Technology, Vol 251 (2018), pp:12-19.

      [4] D. Yang, G. Zhang, “Deposition time and thermal cycles of fabricating thin-wall steel parts by double electrode GMAW based additive manufacturingâ€, MATEC Web of Conferences (2017), 88, 01007.

      [5] J.R.R Honnige, P.A. Colegrove, S. Ganguly, E, Eimer, S. Kabra, S. Williams, et all, “Control of residual stress and distortion in aluminium wire + arc additive manufacturing with rollingâ€, Additive Manufacturing, Vol 22 (2018).

      [6] G. Venturini, F. Montevecchi, A. Scippa, G. Campatelli., “Optimization of WAAM deposition patterns for T-crossing featuresâ€, Procedia CIRP, Vol 55 (2016), pp:95-100.

      [7] E.R Denlinger, P. Michaleris, “Effect of stress relaxation on distortion in additive manufacturing processâ€, Additive Manufacturing, Vol 12a (2016), pp:51-59

      [8] G. Tham, N.F Mohammad Nor, M. Faruqi, J. Saedon, “Prediction of weld bead geometry for small-wire submerged arc welding in 1G positionâ€, Journal of Mechanical Engineering, Vol 3(2) (2017), pp:145-156

      [9] Z. Hu, X. Qin, T. Shao, “Welding thermal simulation and metallurgical characteristic analysis in WAAM for 5CrNiMo hot forging die remanufacturingâ€, Procedia Engineering, Vol 207 (2017), pp:2203-2208.

      [10] J. Francis, H. Stone, S. Kundu, R. Rogge, H. Bhadesdhia, Et al. Transformation temperatures and welding residual stresses in ferritic steelsâ€, ASME 2007 American Society of Mechanical Engineers (2007), pp: 949-956.

      [11] H. Dai, J. Francis, et al “Characterizing phase transformation and their effects on ferritic weld residual stresses with x-rays and neutronsâ€, Metalurgical and Material Transaction, Vol 39A (2008), pp:3070-3078.

      [12] Pedro P.R Filho, T.S Cavalcante, V.H Costa De Alburquerque, P.C Cortez,“Measurement of welding dilution from images using active contoursâ€, Conference Paper (2009).

      [13] D. Andud, N. Nurdin, Y.H.P. Manurung, M.Faiz M, S. Saidin , “Parameters Identification for Weld Quality, Strength and Fatigue Life Enhancement on HSLA (2460G2+M) using Manual GMAW followed by HFMI/PITâ€, Journals of Mechanical Engineering, Vol SI 5-4 (2018).

      [14] Y.H.P Manurung, “Database of Common Material Propertiesâ€, Unpublished (2015).

      [15] W. Jiang, W. Chen, W. Woo, Et All, “Effects on low-temperature and transformation-induced plasticity on weld residual stresses: Numerical study and neutron diffraction measurementâ€, Materials and Design, Vol 147 (2018), pp:65-79.

      [16] C. Pandey, M.M Mahapatra, P. Kumar, “A comparative study of transverse shrinkage stresses and residual stresses in p91 welded pipe including plasticity errorâ€, Archives of Civil and Mechanical Engineering, Vol 18 Issue 3 (2018), pp:1000-1011.

      Montevecchi, G. Venturini, A, Scippa, G. Campatelli , “Finite Element Modelling of Wire-arc-additive-manufacturing processâ€, Procedia CIRP, Vol 55 (2016), pp:109-114.

  • Downloads

  • How to Cite

    P Prajadhiana, K., HP Manurung, Y., Minggu, Z., HS Pengadau, F., Leng Choo, H., Graf, M., Haelsig, A., Adams, T.-E., & P Ishak, D. (2018). Fundamental Analysis on substrate distortion induced by Wire Arc Additive Manufacturing using experiment and nonlinear FEM with simplified bead model. International Journal of Engineering & Technology, 7(4.36), 1578-1582. https://doi.org/10.14419/ijet.v7i4.36.29379