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Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with Enhanced Separation and Deposition Algorithm

This research is devoted to numerical and experimental analysis on deformation of completely removed component induced by wire arc additive manufacturing (WAAM). The component has the form of a hollow and rectangular thin wall made of deposition layer of stainless steel SS316L on top of substrate pl...

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Main Authors: Prajadhiana, Keval P., Taufek, Thoufeili, Rahaman, Wan Emri Wan Abdul, Manurung, Yupiter H. P., Adenan, Mohd Shahriman, Mat, Muhd Faiz, Fuzi, Muhamad Fakhrul Akmal Bin Mohamad, Nasir, Mohamad Ariffudin bin Mohammed, Mohamed, Mohamed Ackiel, Jamaludin, Mohd Fadzil, Triyono, -
Format: Article
Published: Mary Ann Liebert 2024
Subjects:
TJ Mechanical engineering and machinery
Online Access:http://eprints.um.edu.my/47161/
https://doi.org/10.1089/3dp.2023.0033
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spelling my.um.eprints.471612024-12-30T02:59:15Z http://eprints.um.edu.my/47161/ Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with Enhanced Separation and Deposition Algorithm Prajadhiana, Keval P. Taufek, Thoufeili Rahaman, Wan Emri Wan Abdul Manurung, Yupiter H. P. Adenan, Mohd Shahriman Mat, Muhd Faiz Fuzi, Muhamad Fakhrul Akmal Bin Mohamad Nasir, Mohamad Ariffudin bin Mohammed Mohamed, Mohamed Ackiel Jamaludin, Mohd Fadzil Triyono, - TJ Mechanical engineering and machinery This research is devoted to numerical and experimental analysis on deformation of completely removed component induced by wire arc additive manufacturing (WAAM). The component has the form of a hollow and rectangular thin wall made of deposition layer of stainless steel SS316L on top of substrate plate of mild steel S235. In this research, thermomechanical finite element analysis was applied with Goldak's double ellipsoid as heat-source model and isotropic hardening rule based on von-Mises yield criterion. A specialized numerical simulation software Simufact.Welding 2021 (SW) was utilized in developing the numerical model and the simulation of process enhanced with separation and deposition algorithm to predict the component deformation after removal of substrate. On determining the best possible mesh size, a sensitivity analysis was conducted before the advanced stage of model development. An advanced material modeling, the data of which were obtained based on the chemical composition of the evolved SS316L sample, was developed using an advanced material modeling software JMATPRO. For verification purpose, a series of WAAM experiments using robotic GMAW with synergic power source were conducted followed by the removal of substrate from component using machining process. Furthermore, component distortion was measured using industrial noncontact 3D scanner with structured blue light to fully capture the upper section deformation and compared with result of numerical computation. It can be concluded that this novel distortion analysis method using thermomechanical numerical computation with evolved material property and modified algorithms for substrate removal exhibits a surface deviation in vertical direction between 0.05 and 2.16 mm with acceptable pointwise and average error percentage of up to 3%. Mary Ann Liebert 2024-08 Article PeerReviewed Prajadhiana, Keval P. and Taufek, Thoufeili and Rahaman, Wan Emri Wan Abdul and Manurung, Yupiter H. P. and Adenan, Mohd Shahriman and Mat, Muhd Faiz and Fuzi, Muhamad Fakhrul Akmal Bin Mohamad and Nasir, Mohamad Ariffudin bin Mohammed and Mohamed, Mohamed Ackiel and Jamaludin, Mohd Fadzil and Triyono, - (2024) Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with Enhanced Separation and Deposition Algorithm. 3D Printing and Additive Manufacturing, 11 (4). e1616-e1628. ISSN 2329-7662, DOI https://doi.org/10.1089/3dp.2023.0033 <https://doi.org/10.1089/3dp.2023.0033>. https://doi.org/10.1089/3dp.2023.0033 10.1089/3dp.2023.0033
institution Universiti Malaya
building UM Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Malaya
content_source UM Research Repository
url_provider http://eprints.um.edu.my/
topic TJ Mechanical engineering and machinery
spellingShingle TJ Mechanical engineering and machinery
Prajadhiana, Keval P.
Taufek, Thoufeili
Rahaman, Wan Emri Wan Abdul
Manurung, Yupiter H. P.
Adenan, Mohd Shahriman
Mat, Muhd Faiz
Fuzi, Muhamad Fakhrul Akmal Bin Mohamad
Nasir, Mohamad Ariffudin bin Mohammed
Mohamed, Mohamed Ackiel
Jamaludin, Mohd Fadzil
Triyono, -
Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with Enhanced Separation and Deposition Algorithm
description This research is devoted to numerical and experimental analysis on deformation of completely removed component induced by wire arc additive manufacturing (WAAM). The component has the form of a hollow and rectangular thin wall made of deposition layer of stainless steel SS316L on top of substrate plate of mild steel S235. In this research, thermomechanical finite element analysis was applied with Goldak's double ellipsoid as heat-source model and isotropic hardening rule based on von-Mises yield criterion. A specialized numerical simulation software Simufact.Welding 2021 (SW) was utilized in developing the numerical model and the simulation of process enhanced with separation and deposition algorithm to predict the component deformation after removal of substrate. On determining the best possible mesh size, a sensitivity analysis was conducted before the advanced stage of model development. An advanced material modeling, the data of which were obtained based on the chemical composition of the evolved SS316L sample, was developed using an advanced material modeling software JMATPRO. For verification purpose, a series of WAAM experiments using robotic GMAW with synergic power source were conducted followed by the removal of substrate from component using machining process. Furthermore, component distortion was measured using industrial noncontact 3D scanner with structured blue light to fully capture the upper section deformation and compared with result of numerical computation. It can be concluded that this novel distortion analysis method using thermomechanical numerical computation with evolved material property and modified algorithms for substrate removal exhibits a surface deviation in vertical direction between 0.05 and 2.16 mm with acceptable pointwise and average error percentage of up to 3%.
format Article
author Prajadhiana, Keval P.
Taufek, Thoufeili
Rahaman, Wan Emri Wan Abdul
Manurung, Yupiter H. P.
Adenan, Mohd Shahriman
Mat, Muhd Faiz
Fuzi, Muhamad Fakhrul Akmal Bin Mohamad
Nasir, Mohamad Ariffudin bin Mohammed
Mohamed, Mohamed Ackiel
Jamaludin, Mohd Fadzil
Triyono, -
author_facet Prajadhiana, Keval P.
Taufek, Thoufeili
Rahaman, Wan Emri Wan Abdul
Manurung, Yupiter H. P.
Adenan, Mohd Shahriman
Mat, Muhd Faiz
Fuzi, Muhamad Fakhrul Akmal Bin Mohamad
Nasir, Mohamad Ariffudin bin Mohammed
Mohamed, Mohamed Ackiel
Jamaludin, Mohd Fadzil
Triyono, -
author_sort Prajadhiana, Keval P.
title Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with Enhanced Separation and Deposition Algorithm
title_short Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with Enhanced Separation and Deposition Algorithm
title_full Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with Enhanced Separation and Deposition Algorithm
title_fullStr Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with Enhanced Separation and Deposition Algorithm
title_full_unstemmed Distortion Analysis Method for Wire Arc Additive Manufacturing Component Using Thermomechanical Computation with Enhanced Separation and Deposition Algorithm
title_sort distortion analysis method for wire arc additive manufacturing component using thermomechanical computation with enhanced separation and deposition algorithm
publisher Mary Ann Liebert
publishDate 2024
url http://eprints.um.edu.my/47161/
https://doi.org/10.1089/3dp.2023.0033
_version_ 1819909893733220352
score 13.223943

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