Residual Stress and Deformation Modelling for Metal Additive Manufacturing Processes

Abstract

Metal additive Manufacturing has gained increasing attention in the area of rapid manufacturing and repairing. This process involves extremely high thermal gradients and heat and cooling rate, resulting in residual stresses and distortion. This paper presents a 3D sequentially coupled thermo-mechanical finite element model to predict residual stresses and deformations. The temperature distribution, thermal stress field and geometry deformation across domain are illustrated. The effect of deposition parameters on residual stress and deflections are also explored. A set of validation experiments for mechanical effects were conducted using laser displacement sensor. The comparisons between the simulated and experimental results show good agreement.

Meeting Name

World Congress on Mechanical, Chemical, and Material Engineering, MCM 2015 (2015: Jul. 20-21, Barcelona, Spain)

Department(s)

Mechanical and Aerospace Engineering

Comments

This work was partially funded through NASA's Fundamental Aeronautics Program, Fixed Wing Project, under NRA NNX11AI73A, Boeing, and Rolls Royce. The authors would like to acknowledge William J. Seufzer and Karen Taminger of NASA Langley Research Center for their critical advice and mentorship. Support from Missouri S&T's Intelligent Systems Center, Material Research Center, and Manufacturing Engineering program is also greatly appreciated.

Keywords and Phrases

Additive manufacturing; Deformation; Experimental validation; Finite element analysis; Residual stress

International Standard Book Number (ISBN)

978-1-927877-17-3

International Standard Serial Number (ISSN)

2369-8136

Document Type

Article - Conference proceedings

Document Version

Citation

File Type

text

Language(s)

English

Rights

© 2015 Avestia Publishing, All rights reserved.

Publication Date

01 Jul 2015

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