Modelling and Simulation of Wire DED Additive Manufacturing Process

Wire Arc Additive Manufacturing (WAAM) technology has great application potential in the aerospace and automotive industries. The main challenges that substantially impede the widespread use of this technology are the residual stresses in additively manufactured (AM) metal parts. Simulation and investigation studies are carried out to analyze the residual stresses. The present study has developed a finite element model that predicts the residual stress distribution and temperature fields in plates. Goldak’s Heat source model is used to predict the residual stresses and thermal cycles on the SUS 304 and the Python run script is developed to run the model. It has been found that the residual stresses developed during the simulation are 381 MPa and under the yield stress of the material. The simulation has been carried out in the ABAQUS CAE 2020 Software. The maximum yield stress developed in the plate is 679 MPa and the maximum principle stress is 285 MPa. The study has focused on the effort, which is required to establish a relationship between the moving heat source model and residual stresses which helps researchers working in this area to get an insight into the FEM of wire arc additive manufacturing.