Finite element modelling of Wire-Arc-Additive-Manufacturing process

Authors: Filippo Montevecchi, Giuseppe Venturini, Antonio Scippa, Gianni Campatelli

Keywords: Welding; Finite element method (FEM)

Purpose: Obtain more accurate results with a WAAM modelling strategy based on a novel heat source model that takes into account the actual power distribution between filler and base materials.

Design/methodology/approach: the heat transfer from the arc to the molten pool is simulated using a heat source model, which prescribes a heat generation per unit volume in the molten pool region. Material deposition is taken into account by means of specific elements activation algorithms. In this paper, the WAAM process is simulated using a novel definition of the heat source, based on a modified Goldak model, in order to have a more realistic heat flow distribution in the filler material.

Findings: this model has a better correlation with the experimental results than the previous models.

Benefits: proposed modelling results are in general agreement with the experimental ones, allowing to achieve an higher accuracy with respect to the traditional technique.

Practical implications: proposed process modelling allows to accurately simulate the WAAM process, without the need to perform time-consuming tuning operations to identify heat source parameters.

Full reference: MONTEVECCHI, Filippo, et al. Finite element modelling of wire-arc-additive-manufacturing process. Procedia Cirp, 2016, 55: 109-114.

Link: www.sciencedirect.com/science/article/pii/S2212827116309131