Distribution of temperature and residual stresses in GMA-DED based wire-arc additive manufacturing
ISSN: 1355-2546
Article publication date: 31 July 2023
Issue publication date: 27 November 2023
Abstract
Purpose
Gas metal arc-based directed energy deposition (GMA-DED) process experiences residual stress (RS) developed due to heat accumulation during successive layer deposition as a significant challenge. To address that, monitoring of transient temperature distribution concerning time is a critical input. Finite element analysis (FEA) is considered a decisive engineering tool in quantifying temperature and RS in all manufacturing processes. However, computational time and prediction accuracy has always been a matter of concern for FEA-based prediction of responses in the GMA-DED process. Therefore, this study aims to investigate the effect of finite element mesh variations on the developed RS in the GMA-DED process.
Design/methodology/approach
The variation in the element shape functions, i.e. linear- and quadratic-interpolation elements, has been used to model a single-track 10-layered thin-walled component in Ansys parametric design language. Two cases have been proposed in this study: Case 1 has been meshed with the linear-interpolation elements and Case 2 has been meshed with the combination of linear- and quadratic-interpolation elements. Furthermore, the modelled responses are authenticated with the experimental results measured through the data acquisition system for temperature and RS.
Findings
A good agreement of temperature and RS profile has been observed between predicted and experimental values. Considering similar parameters, Case 1 produced an average error of 4.13%, whereas Case 2 produced an average error of 23.45% in temperature prediction. Besides, comparing the longitudinal stress in the transverse direction for Cases 1 and 2 produced an error of 8.282% and 12.796%, respectively.
Originality/value
To avoid the costly and time-taking experimental approach, the experts have suggested the utilization of numerical methods in the design optimization of engineering problems. The FEA approach, however, is a subtle tool, still, it faces high computational cost and low accuracy based on the choice of selected element technology. This research can serve as a basis for the choice of element technology which can predict better responses in the thermo-mechanical modelling of the GMA-DED process.
Keywords
Acknowledgements
This work is supported by the IITG Technology Innovation and Development Foundation (IITG TI&DF), which has been set up at IIT Guwahati as a part of the National Mission on Interdisciplinary Cyber-Physical Systems (NMICPS). IITG TI&DF is undertaking research, development, and training activities on Technologies for Under Water Exploration with financial assistance from the Department of Science and Technology, India through grant number DST/NMICPS/TIH12/IITG/2020. Authors gratefully acknowledge the support provided for the present work.
Since acceptance of this article, the following author has updated their affiliation: Shekhar Srivastava is at the Technology Innovation Hub, IITG TI & DF, Guwahati, India; Munish Kumar Gupta is at the Department of Mechanical Engineering, Graphic Era (Deemed to be university), Dehradun, India.
Citation
Srivastava, S., Garg, R.K., Sachdeva, A., Sharma, V.S., Singh, S. and Gupta, M.K. (2023), "Distribution of temperature and residual stresses in GMA-DED based wire-arc additive manufacturing", Rapid Prototyping Journal, Vol. 29 No. 10, pp. 2001-2018. https://doi.org/10.1108/RPJ-01-2023-0032
Publisher
:Emerald Publishing Limited
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