Development of segmented cambered body heat source model in numerical simulations of aluminum alloy cylindrical walls

DONG Mingye; ZHAO Yue; JIA Jinlong; LI Quan; WANG Fude; WU Aiping

doi:10.16511/j.cnki.qhdxxb.2019.22.024

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Journal of Tsinghua University(Science and Technology) ›› 2019, Vol. 59 ›› Issue (10) : 823-830. DOI: 10.16511/j.cnki.qhdxxb.2019.22.024

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Development of segmented cambered body heat source model in numerical simulations of aluminum alloy cylindrical walls

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Abstract

To improve the wire and arc additive manufacturing (WAAM) numerical simulation efficiency of aluminum alloy cylindrical walls, a segmented cambered body heat source model was developed with its mathematical derivation clarified based on segmentation on circular path of the Goldak body heat source with secondary development on ABAQUS. The moving heat source, the material models and the boundary conditions were verified in a finite element model with the numerical results agreeing well with experimental data. The accuracy and efficiency of the WAAM numerical simulations were evaluated using three segmented computing strategies. Comparisons of the results using the three segmented computing strategies with those using the moving heat source show that the thermal cycles are similar with peak temperatures having less than 8% errors, the residual stress distributions are consistent and the results are not sensitive to the number of segments in the segmented sources. The use of one, four or eight segmented heat sources reduces the total computational time by 98.24%, 77.51% and 65.96%.

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wire and arc additive manufacturing / aluminum alloy / cylindrical wall / numerical simulation / segmented cambered body heat source

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DONG Mingye, ZHAO Yue, JIA Jinlong, LI Quan, WANG Fude, WU Aiping. Development of segmented cambered body heat source model in numerical simulations of aluminum alloy cylindrical walls[J]. Journal of Tsinghua University(Science and Technology). 2019, 59(10): 823-830 https://doi.org/10.16511/j.cnki.qhdxxb.2019.22.024

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