Wire arc additive manufacturing (WAAM) is a widely-used method for 3D printing and repairing metal parts, known for its high deposition rates and ability to fabricate complex geometries with ease. This study focuses on analyzing temperature evolution at a focal point resulting from build geometry. It achieves this by simulating a macro-level model created using the WAAM process, employing the AM DED module in ANSYS, and validating the results through experimentation. The experiment is conducted by building a single layer consisting of four beads on a substrate plate with a length of 80 mm and a width of 6 mm. Beads were built up on a substrate plate made of mild steel with ER70S-6 wire of 0.8 mm diameter. During the development of the layer, a hatch spacing of 4 mm with a 2 mm overlap is ensured. K-type thermocouples at the focal location of the substrate plate are used to monitor the temperature evolution. A finite element model is developed considering the temperature-dependent material properties and convection and radiation heat loss from the substrate plate and build geometry. The maximum temperature of 127 °C is recorded in the experiment and simulation at the focal location. The appropriate clustering type, clustering volume, and print direction are selected in the simulation. The temperature evolution in the simulation is validated with the experimental data. The temperature evolution achieved through the simulation with the novel approach is an area that can be improved in the further studies.

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Thermal Analysis of ER70S-6 Wire Deposition in Wire Arc Additive Manufacturing: An Experimental and Numerical Investigation

  • Banala Dharmista,
  • Vineesh Vishnu,
  • Anoop A. Pillai,
  • Amit Kumar Rai,
  • K. P. Vineesh,
  • P. Ashok Kumar,
  • Bijoy Rajak

摘要

Wire arc additive manufacturing (WAAM) is a widely-used method for 3D printing and repairing metal parts, known for its high deposition rates and ability to fabricate complex geometries with ease. This study focuses on analyzing temperature evolution at a focal point resulting from build geometry. It achieves this by simulating a macro-level model created using the WAAM process, employing the AM DED module in ANSYS, and validating the results through experimentation. The experiment is conducted by building a single layer consisting of four beads on a substrate plate with a length of 80 mm and a width of 6 mm. Beads were built up on a substrate plate made of mild steel with ER70S-6 wire of 0.8 mm diameter. During the development of the layer, a hatch spacing of 4 mm with a 2 mm overlap is ensured. K-type thermocouples at the focal location of the substrate plate are used to monitor the temperature evolution. A finite element model is developed considering the temperature-dependent material properties and convection and radiation heat loss from the substrate plate and build geometry. The maximum temperature of 127 °C is recorded in the experiment and simulation at the focal location. The appropriate clustering type, clustering volume, and print direction are selected in the simulation. The temperature evolution in the simulation is validated with the experimental data. The temperature evolution achieved through the simulation with the novel approach is an area that can be improved in the further studies.