Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products
A new method of controlling the residual stress in laser directed energy deposition additive manufacturing (DED AM) products proposed based on constraints used in manufacturing and the substrate design. The simulation results of the residual stress, which were validated with the experimental measure...
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MDPI AG
2022-03-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/12/3/462 |
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| author | Hang Jing Peng Ge Zhao Zhang Jun-Qi Chen Zhong-Ming Liu Wei-Wei Liu |
| author_facet | Hang Jing Peng Ge Zhao Zhang Jun-Qi Chen Zhong-Ming Liu Wei-Wei Liu |
| author_sort | Hang Jing |
| collection | DOAJ |
| description | A new method of controlling the residual stress in laser directed energy deposition additive manufacturing (DED AM) products proposed based on constraints used in manufacturing and the substrate design. The simulation results of the residual stress, which were validated with the experimental measured data, showed that weaker constraints on the substrate could greatly decrease the residual stress in the laser DED AM products. In addition, by designing local reduced thickness regions into the substrate, such as long strip holes or support legs, the residual stress in DED AM products could be further decreased. In this study, when long strip holes were designed in the substrate, the tensile residual stress was decreased by 28%. An even smaller amount of residual stress was achieved when the design structure was changed to support legs. The tensile residual stress decreased by more than 30%. The fewer support legs, the smaller the residual stress. The residual stress in DED AM products could be well-controlled by design, while the stiffness can be weakened with fewer constraints. |
| first_indexed | 2024-03-09T13:19:44Z |
| format | Article |
| id | doaj.art-bb1f6c24f8ff435a90275a73f4231ec5 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-09T13:19:44Z |
| publishDate | 2022-03-01 |
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| record_format | Article |
| series | Metals |
| spelling | doaj.art-bb1f6c24f8ff435a90275a73f4231ec52023-11-30T21:31:37ZengMDPI AGMetals2075-47012022-03-0112346210.3390/met12030462Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled ProductsHang Jing0Peng Ge1Zhao Zhang2Jun-Qi Chen3Zhong-Ming Liu4Wei-Wei Liu5College of Civil Engineering and Architecture, Henan University of Technology, Zhengzhou 450000, ChinaCollege of Civil Engineering and Architecture, Henan University of Technology, Zhengzhou 450000, ChinaState Key Laboratory of Structural Analysis for Industrial Equipment, Department of Engineering Mechanics, Faculty of Vehicle Engineering and Mechanics, Dalian University of Technology, Dalian 116024, ChinaCollege of Civil Engineering and Architecture, Henan University of Technology, Zhengzhou 450000, ChinaZhengzhou Research Institute of Mechanical Engineering Co., Ltd., Zhengzhou 450052, ChinaSchool of Mechanical Engineering, Dalian University of Technology, Dalian 116024, ChinaA new method of controlling the residual stress in laser directed energy deposition additive manufacturing (DED AM) products proposed based on constraints used in manufacturing and the substrate design. The simulation results of the residual stress, which were validated with the experimental measured data, showed that weaker constraints on the substrate could greatly decrease the residual stress in the laser DED AM products. In addition, by designing local reduced thickness regions into the substrate, such as long strip holes or support legs, the residual stress in DED AM products could be further decreased. In this study, when long strip holes were designed in the substrate, the tensile residual stress was decreased by 28%. An even smaller amount of residual stress was achieved when the design structure was changed to support legs. The tensile residual stress decreased by more than 30%. The fewer support legs, the smaller the residual stress. The residual stress in DED AM products could be well-controlled by design, while the stiffness can be weakened with fewer constraints.https://www.mdpi.com/2075-4701/12/3/462residual stressthermal distortionsubstrate structuredirected energy deposition |
| spellingShingle | Hang Jing Peng Ge Zhao Zhang Jun-Qi Chen Zhong-Ming Liu Wei-Wei Liu Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products Metals residual stress thermal distortion substrate structure directed energy deposition |
| title | Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products |
| title_full | Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products |
| title_fullStr | Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products |
| title_full_unstemmed | Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products |
| title_short | Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products |
| title_sort | numerical studies of the effects of the substrate structure on the residual stress in laser directed energy additive manufacturing of thin walled products |
| topic | residual stress thermal distortion substrate structure directed energy deposition |
| url | https://www.mdpi.com/2075-4701/12/3/462 |
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