Simulating the build shape for a shell structure for wire and arc additive manufacturing using the bead cross-section model
Wire and arc additive manufacturing is one of the additive manufacturing processes based on arc welding technology and is particularly useful in fabricating large-sized die and prototype machine parts. In general, a computer-aided manufacturing (CAM) system is required not only to generate the depos...
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| Format: | Article |
| Language: | English |
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The Japan Society of Mechanical Engineers
2021-01-01
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| Series: | Journal of Advanced Mechanical Design, Systems, and Manufacturing |
| Subjects: | |
| Online Access: | https://www.jstage.jst.go.jp/article/jamdsm/15/1/15_2021jamdsm0001/_pdf/-char/en |
| _version_ | 1811225789935386624 |
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| author | Takeyuki ABE Hiroyuki SASAHARA |
| author_facet | Takeyuki ABE Hiroyuki SASAHARA |
| author_sort | Takeyuki ABE |
| collection | DOAJ |
| description | Wire and arc additive manufacturing is one of the additive manufacturing processes based on arc welding technology and is particularly useful in fabricating large-sized die and prototype machine parts. In general, a computer-aided manufacturing (CAM) system is required not only to generate the deposition path as a numerical control data but also to estimate the shape of the build structure. Estimating the build structure before the actual fabrication can help determine the optimal process parameters. However, the build structure simulated using the existing CAM system may not be sufficiently accurate, because the bead geometry is influenced by various factors, such as the process parameters, material type, target shape, and the location in which the molten metal is deposited. In this scenario, it is challenging to obtain the optimal process parameters based on the build structure simulation results. Therefore, in this study, a two-dimensional bead cross-section model was established, in which the bead accumulation was considered to fabricate a shell structure, and a build shell structure simulator was developed. The temperature distribution was numerically simulated to obtain the relationship between a process parameter and the bead cross-section geometry without conducting destructive inspection. Furthermore, the accuracy of the simulator was investigated. The results indicated that the accuracy of the simulator was approximately ±1 mm in the area with a low influence of the deposition start and stop processes. |
| first_indexed | 2024-04-12T09:13:09Z |
| format | Article |
| id | doaj.art-d54fb373695941f6bceae2b0ef371731 |
| institution | Directory Open Access Journal |
| issn | 1881-3054 |
| language | English |
| last_indexed | 2024-04-12T09:13:09Z |
| publishDate | 2021-01-01 |
| publisher | The Japan Society of Mechanical Engineers |
| record_format | Article |
| series | Journal of Advanced Mechanical Design, Systems, and Manufacturing |
| spelling | doaj.art-d54fb373695941f6bceae2b0ef3717312022-12-22T03:38:55ZengThe Japan Society of Mechanical EngineersJournal of Advanced Mechanical Design, Systems, and Manufacturing1881-30542021-01-01151JAMDSM0001JAMDSM000110.1299/jamdsm.2021jamdsm0001jamdsmSimulating the build shape for a shell structure for wire and arc additive manufacturing using the bead cross-section modelTakeyuki ABE0Hiroyuki SASAHARA1Graduate school of Science and Engineering, Saitama UniversityDepartment of Mechanical Systems Engineering, Tokyo University of Agriculture and TechnologyWire and arc additive manufacturing is one of the additive manufacturing processes based on arc welding technology and is particularly useful in fabricating large-sized die and prototype machine parts. In general, a computer-aided manufacturing (CAM) system is required not only to generate the deposition path as a numerical control data but also to estimate the shape of the build structure. Estimating the build structure before the actual fabrication can help determine the optimal process parameters. However, the build structure simulated using the existing CAM system may not be sufficiently accurate, because the bead geometry is influenced by various factors, such as the process parameters, material type, target shape, and the location in which the molten metal is deposited. In this scenario, it is challenging to obtain the optimal process parameters based on the build structure simulation results. Therefore, in this study, a two-dimensional bead cross-section model was established, in which the bead accumulation was considered to fabricate a shell structure, and a build shell structure simulator was developed. The temperature distribution was numerically simulated to obtain the relationship between a process parameter and the bead cross-section geometry without conducting destructive inspection. Furthermore, the accuracy of the simulator was investigated. The results indicated that the accuracy of the simulator was approximately ±1 mm in the area with a low influence of the deposition start and stop processes.https://www.jstage.jst.go.jp/article/jamdsm/15/1/15_2021jamdsm0001/_pdf/-char/enadditive manufacturingdirected energy depositionweldingarc dischargewire materialcam |
| spellingShingle | Takeyuki ABE Hiroyuki SASAHARA Simulating the build shape for a shell structure for wire and arc additive manufacturing using the bead cross-section model Journal of Advanced Mechanical Design, Systems, and Manufacturing additive manufacturing directed energy deposition welding arc discharge wire material cam |
| title | Simulating the build shape for a shell structure for wire and arc additive manufacturing using the bead cross-section model |
| title_full | Simulating the build shape for a shell structure for wire and arc additive manufacturing using the bead cross-section model |
| title_fullStr | Simulating the build shape for a shell structure for wire and arc additive manufacturing using the bead cross-section model |
| title_full_unstemmed | Simulating the build shape for a shell structure for wire and arc additive manufacturing using the bead cross-section model |
| title_short | Simulating the build shape for a shell structure for wire and arc additive manufacturing using the bead cross-section model |
| title_sort | simulating the build shape for a shell structure for wire and arc additive manufacturing using the bead cross section model |
| topic | additive manufacturing directed energy deposition welding arc discharge wire material cam |
| url | https://www.jstage.jst.go.jp/article/jamdsm/15/1/15_2021jamdsm0001/_pdf/-char/en |
| work_keys_str_mv | AT takeyukiabe simulatingthebuildshapeforashellstructureforwireandarcadditivemanufacturingusingthebeadcrosssectionmodel AT hiroyukisasahara simulatingthebuildshapeforashellstructureforwireandarcadditivemanufacturingusingthebeadcrosssectionmodel |