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Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification / Keval Priapratama Prajadhiana … [et al.]

This paper deals with a principal development of virtual manufacturing (VM) procedure to predict substrate distortion induced by Wire Arc Additive Manufacturing (WAAM) process. In this procedure, a hollow shape is designed in a thin-walled form made of stainless steel. The procedure starts with geom...

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Main Authors: Prajadhiana, Keval Priaratama, Manurung, Yupiter HP, Bauer, Alexander, Mohamed, Mohamed Ackiel
Format: Article
Language:English
Published: Smart Manufacturing Research Institute (SMRI) 2021
Online Access:https://ir.uitm.edu.my/id/eprint/66471/1/66471.pdf
https://ir.uitm.edu.my/id/eprint/66471/
https://jaeds.uitm.edu.my/
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spelling my.uitm.ir.664712023-01-15T11:36:27Z https://ir.uitm.edu.my/id/eprint/66471/ Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification / Keval Priapratama Prajadhiana … [et al.] Prajadhiana, Keval Priaratama Manurung, Yupiter HP Bauer, Alexander Mohamed, Mohamed Ackiel This paper deals with a principal development of virtual manufacturing (VM) procedure to predict substrate distortion induced by Wire Arc Additive Manufacturing (WAAM) process. In this procedure, a hollow shape is designed in a thin-walled form made of stainless steel. The procedure starts with geometrical modelling of WAAM component consisting of twenty-five deposited layers with austenitic stainless-steel wire SS316L as feedstock and SS304 as substrate material. The hollow shape is modelled based on simplified rectangular mesh geometry with identical specimen dimensions during the experiment. Material model to be defined can be retrieved directly from a database or by conducting a basic experiment to obtain the evolution of material composition, characterized using Scanning Electron Microscopy (SEM) with Energy Dispersive X-ray (EDX) analysis, and generated using advanced modelling software JMATPRO for creating new properties including the flow curves. Further, a coupled thermomechanical solution is adopted, including phase-change phenomena defined in latent heat, whereby temperature history due to successive layer deposition is simulated by coupling the heat transfer and mechanical analysis. Transient thermal distribution is calibrated from an experiment obtained from thermocouple analysis at two reference measurement locations. New heat transfer coefficients are to be adjusted to reflect actual temperature change. As the following procedure prior to simulation execution, a sensitivity analysis was conducted to find the optimal number of elements or mesh size towards temperature distribution. The last procedure executes the thermomechanical numerical simulation and analysis the post-processing results. Based on all aspects in VM procedures and boundary conditions, WAAM distortion is verified using a robotic welding system equipped with a pulsed power source. The experimental substrate distortion is measured at various points before and after the process. It can be concluded based on the adjusted model and experimental verification that using nonlinear numerical computation, the prediction of substrate distortion with evolved material property of component yields far better result which has the relative error less than 11% in a comparison to database material which has 22%, almost doubled the inaccuracy. Smart Manufacturing Research Institute (SMRI) 2021-09 Article PeerReviewed text en https://ir.uitm.edu.my/id/eprint/66471/1/66471.pdf Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification / Keval Priapratama Prajadhiana … [et al.]. (2021) Journal of Applied Engineering Design & Simulation (JAEDS), 1 (1): 11. pp. 74-87. ISSN 2805-5756 https://jaeds.uitm.edu.my/
institution Universiti Teknologi Mara
building Tun Abdul Razak Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Teknologi Mara
content_source UiTM Institutional Repository
url_provider http://ir.uitm.edu.my/
language English
description This paper deals with a principal development of virtual manufacturing (VM) procedure to predict substrate distortion induced by Wire Arc Additive Manufacturing (WAAM) process. In this procedure, a hollow shape is designed in a thin-walled form made of stainless steel. The procedure starts with geometrical modelling of WAAM component consisting of twenty-five deposited layers with austenitic stainless-steel wire SS316L as feedstock and SS304 as substrate material. The hollow shape is modelled based on simplified rectangular mesh geometry with identical specimen dimensions during the experiment. Material model to be defined can be retrieved directly from a database or by conducting a basic experiment to obtain the evolution of material composition, characterized using Scanning Electron Microscopy (SEM) with Energy Dispersive X-ray (EDX) analysis, and generated using advanced modelling software JMATPRO for creating new properties including the flow curves. Further, a coupled thermomechanical solution is adopted, including phase-change phenomena defined in latent heat, whereby temperature history due to successive layer deposition is simulated by coupling the heat transfer and mechanical analysis. Transient thermal distribution is calibrated from an experiment obtained from thermocouple analysis at two reference measurement locations. New heat transfer coefficients are to be adjusted to reflect actual temperature change. As the following procedure prior to simulation execution, a sensitivity analysis was conducted to find the optimal number of elements or mesh size towards temperature distribution. The last procedure executes the thermomechanical numerical simulation and analysis the post-processing results. Based on all aspects in VM procedures and boundary conditions, WAAM distortion is verified using a robotic welding system equipped with a pulsed power source. The experimental substrate distortion is measured at various points before and after the process. It can be concluded based on the adjusted model and experimental verification that using nonlinear numerical computation, the prediction of substrate distortion with evolved material property of component yields far better result which has the relative error less than 11% in a comparison to database material which has 22%, almost doubled the inaccuracy.
format Article
author Prajadhiana, Keval Priaratama
Manurung, Yupiter HP
Bauer, Alexander
Mohamed, Mohamed Ackiel
spellingShingle Prajadhiana, Keval Priaratama
Manurung, Yupiter HP
Bauer, Alexander
Mohamed, Mohamed Ackiel
Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification / Keval Priapratama Prajadhiana … [et al.]
author_facet Prajadhiana, Keval Priaratama
Manurung, Yupiter HP
Bauer, Alexander
Mohamed, Mohamed Ackiel
author_sort Prajadhiana, Keval Priaratama
title Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification / Keval Priapratama Prajadhiana … [et al.]
title_short Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification / Keval Priapratama Prajadhiana … [et al.]
title_full Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification / Keval Priapratama Prajadhiana … [et al.]
title_fullStr Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification / Keval Priapratama Prajadhiana … [et al.]
title_full_unstemmed Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification / Keval Priapratama Prajadhiana … [et al.]
title_sort methodical procedure of virtual manufacturing for analysing waam distortion along with experimental verification / keval priapratama prajadhiana … [et al.]
publisher Smart Manufacturing Research Institute (SMRI)
publishDate 2021
url https://ir.uitm.edu.my/id/eprint/66471/1/66471.pdf
https://ir.uitm.edu.my/id/eprint/66471/
https://jaeds.uitm.edu.my/
_version_ 1755876022901800960
score 13.211869

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