Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components
High pressure multi-layer rolling is an effective method to reduce residual stress and distortion in metallic components built by wire arc additive manufacturing (WAAM). However, the mechanisms of the reduction in residual stress and distortion during multi-layer rolling are not well understood. Con...
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-01-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/11/1/402 |
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| author | Valeriy Gornyakov Yongle Sun Jialuo Ding Stewart Williams |
| author_facet | Valeriy Gornyakov Yongle Sun Jialuo Ding Stewart Williams |
| author_sort | Valeriy Gornyakov |
| collection | DOAJ |
| description | High pressure multi-layer rolling is an effective method to reduce residual stress and distortion in metallic components built by wire arc additive manufacturing (WAAM). However, the mechanisms of the reduction in residual stress and distortion during multi-layer rolling are not well understood. Conventional finite element models for rolling are highly inefficient, hindering the simulation of multi-layer rolling for large WAAM components. This study aims to identify the most suitable modelling technique for finite element analysis of large WAAM component rolling. Four efficient rolling models were developed, and their efficiency and accuracy were compared with reference to a conventional large-scale rolling model (i.e., control model) for a WAAM built wall. A short-length transient model with fewer elements than the control model was developed to reduce computational time. Accurate predictions of stress and strain and a reduction in computational time by 96.5% were achieved using the short-length model when an implicit method for numerical solution was employed, while similar efficiency but less accurate prediction was obtained when an explicit solution method was adopted. A Eulerian steady-state model was also developed, which was slightly less efficient (95.91% reduction in computational time) but was much less accurate due to unrealistic representation of rolling process. The applicability of a 2D rolling model was also examined and it was found that the 2D model is highly efficient (99.52% time reduction) but less predictive due to the 2D simplification. This study also shows that the rigid roller adopted in the models is beneficial for improving efficiency without sacrificing accuracy. |
| first_indexed | 2024-03-10T13:31:33Z |
| format | Article |
| id | doaj.art-fd85cd330c584e5b801a6d559ec90830 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-10T13:31:33Z |
| publishDate | 2021-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-fd85cd330c584e5b801a6d559ec908302023-11-21T08:02:08ZengMDPI AGApplied Sciences2076-34172021-01-0111140210.3390/app11010402Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured ComponentsValeriy Gornyakov0Yongle Sun1Jialuo Ding2Stewart Williams3Welding Engineering and Laser Processing Centre, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield MK43 0AL, UKWelding Engineering and Laser Processing Centre, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield MK43 0AL, UKWelding Engineering and Laser Processing Centre, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield MK43 0AL, UKWelding Engineering and Laser Processing Centre, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield MK43 0AL, UKHigh pressure multi-layer rolling is an effective method to reduce residual stress and distortion in metallic components built by wire arc additive manufacturing (WAAM). However, the mechanisms of the reduction in residual stress and distortion during multi-layer rolling are not well understood. Conventional finite element models for rolling are highly inefficient, hindering the simulation of multi-layer rolling for large WAAM components. This study aims to identify the most suitable modelling technique for finite element analysis of large WAAM component rolling. Four efficient rolling models were developed, and their efficiency and accuracy were compared with reference to a conventional large-scale rolling model (i.e., control model) for a WAAM built wall. A short-length transient model with fewer elements than the control model was developed to reduce computational time. Accurate predictions of stress and strain and a reduction in computational time by 96.5% were achieved using the short-length model when an implicit method for numerical solution was employed, while similar efficiency but less accurate prediction was obtained when an explicit solution method was adopted. A Eulerian steady-state model was also developed, which was slightly less efficient (95.91% reduction in computational time) but was much less accurate due to unrealistic representation of rolling process. The applicability of a 2D rolling model was also examined and it was found that the 2D model is highly efficient (99.52% time reduction) but less predictive due to the 2D simplification. This study also shows that the rigid roller adopted in the models is beneficial for improving efficiency without sacrificing accuracy.https://www.mdpi.com/2076-3417/11/1/402wire + arc additive manufacturingcomputationally efficient rolling modelimplicit analysisexplicit analysisEulerian analysis2D plane stress model |
| spellingShingle | Valeriy Gornyakov Yongle Sun Jialuo Ding Stewart Williams Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components Applied Sciences wire + arc additive manufacturing computationally efficient rolling model implicit analysis explicit analysis Eulerian analysis 2D plane stress model |
| title | Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components |
| title_full | Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components |
| title_fullStr | Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components |
| title_full_unstemmed | Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components |
| title_short | Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components |
| title_sort | computationally efficient models of high pressure rolling for wire arc additively manufactured components |
| topic | wire + arc additive manufacturing computationally efficient rolling model implicit analysis explicit analysis Eulerian analysis 2D plane stress model |
| url | https://www.mdpi.com/2076-3417/11/1/402 |
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