| About this Abstract |
| Meeting |
2024 AWS Professional Program
|
| Symposium
|
2024 AWS Professional Program
|
| Presentation Title |
Enhanced Prediction of Residual Stress and Distortion by Coupling Molten Pool and Mechanical Models |
| Author(s) |
Aryan Aryan, Diljith P. K., Amitava De, Wei Zhang |
| On-Site Speaker (Planned) |
Aryan Aryan |
| Abstract Scope |
Lightweight aluminum alloys are increasingly used for automotive components such as electric vehicle (EV) battery casings to reduce weight and enhance vehicle efficiency. Wire arc additive manufacturing (WAAM), which supports complex designs and rapid prototyping, is a potential manufacturing process in the fast-paced EV market. The integrity of components produced by WAAM is susceptible to thermal stresses and distortions, which can lead to defects such as delamination and warping. Accurate prediction and management of residual stress and distortion are imperative to preserve the quality and integrity of these parts. Most current models for predicting residual stress and distortion rely on solid mechanics approach based on the finite element method (FEM). The FEM based heat conduction models often fail to accurately predict transient temperature fields due to oversimplified assumptions about molten pool dynamics. Consequently, the accuracy of the predicted residual stress and distortion is adversely affected.
We report here a high-fidelity modeling framework that integrates a computational fluid dynamics (CFD) molten pool model with a mechanical model to improve the prediction of temperature field and consequent thermal stresses in aluminum parts made by WAAM. The molten pool model simulates the layer-by-layer deposition of AA6061 onto a substrate using Volume of Fluid method. The predicted bead profiles along with the transient temperature fields are mapped into the mechanical FEM model that uses progressive element activation method. The integrated CFD-FEM models are applied to simulate the residual stresses in a single wall printed by WAAM reported in the literature. The simulation results are compared to those predicted by the standard FEM models, and the effect of molten pool dynamics on the residual stresses is examined. |
| Proceedings Inclusion? |
Undecided |