An Inherent Strain Method Using Progressive Element Activation for Fast Distortion Calculation in Directed Energy Deposition
The finite element analysis (FEA) simulation of directed energy deposition (DED) processes offers many potential cost savings during the build job optimization process, through, e.g., distortion predictions. However, the biggest challenge is the long calculation time, frequently exceeding the actual...
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MDPI AG
2024-11-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/14/12/1338 |
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| author | Georg Seitz Patrick Bantle Max Biegler Beatrix A. M. Elsner Michael Rethmeier |
| author_facet | Georg Seitz Patrick Bantle Max Biegler Beatrix A. M. Elsner Michael Rethmeier |
| author_sort | Georg Seitz |
| collection | DOAJ |
| description | The finite element analysis (FEA) simulation of directed energy deposition (DED) processes offers many potential cost savings during the build job optimization process, through, e.g., distortion predictions. However, the biggest challenge is the long calculation time, frequently exceeding the actual build time. One way of simplifying the simulation with the aim of reducing the calculation times is the inherent strain method. While this method is already used commercially in the simulation of powder bed-based processes and conventional welding technologies, its use in DED is still the subject of research. In this work, an inverse determination of an inherent strain is carried out on a 20-layer-high, single-track-wide wall, common theories are reviewed, and an approach based on thermal strain is introduced. As a result, the calculation time could be reduced by 83% and the accuracy remained at 92%. |
| format | Article |
| id | doaj-art-05aa828e25a44ed9ae430218718d3ef9 |
| institution | Kabale University |
| issn | 2075-4701 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj-art-05aa828e25a44ed9ae430218718d3ef92024-12-27T14:39:46ZengMDPI AGMetals2075-47012024-11-011412133810.3390/met14121338An Inherent Strain Method Using Progressive Element Activation for Fast Distortion Calculation in Directed Energy DepositionGeorg Seitz0Patrick Bantle1Max Biegler2Beatrix A. M. Elsner3Michael Rethmeier4Fraunhofer Institute for Production Systems and Design Technology (IPK), 10587 Berlin, GermanyFraunhofer Institute for Production Systems and Design Technology (IPK), 10587 Berlin, GermanyFraunhofer Institute for Production Systems and Design Technology (IPK), 10587 Berlin, GermanyHexagon Manufacturing Intelligence GmbH, 21079 Hamburg, GermanyFraunhofer Institute for Production Systems and Design Technology (IPK), 10587 Berlin, GermanyThe finite element analysis (FEA) simulation of directed energy deposition (DED) processes offers many potential cost savings during the build job optimization process, through, e.g., distortion predictions. However, the biggest challenge is the long calculation time, frequently exceeding the actual build time. One way of simplifying the simulation with the aim of reducing the calculation times is the inherent strain method. While this method is already used commercially in the simulation of powder bed-based processes and conventional welding technologies, its use in DED is still the subject of research. In this work, an inverse determination of an inherent strain is carried out on a 20-layer-high, single-track-wide wall, common theories are reviewed, and an approach based on thermal strain is introduced. As a result, the calculation time could be reduced by 83% and the accuracy remained at 92%.https://www.mdpi.com/2075-4701/14/12/1338inherent strain methodsimulationfinite element analysisdirected energy depositionadditive manufacturing |
| spellingShingle | Georg Seitz Patrick Bantle Max Biegler Beatrix A. M. Elsner Michael Rethmeier An Inherent Strain Method Using Progressive Element Activation for Fast Distortion Calculation in Directed Energy Deposition Metals inherent strain method simulation finite element analysis directed energy deposition additive manufacturing |
| title | An Inherent Strain Method Using Progressive Element Activation for Fast Distortion Calculation in Directed Energy Deposition |
| title_full | An Inherent Strain Method Using Progressive Element Activation for Fast Distortion Calculation in Directed Energy Deposition |
| title_fullStr | An Inherent Strain Method Using Progressive Element Activation for Fast Distortion Calculation in Directed Energy Deposition |
| title_full_unstemmed | An Inherent Strain Method Using Progressive Element Activation for Fast Distortion Calculation in Directed Energy Deposition |
| title_short | An Inherent Strain Method Using Progressive Element Activation for Fast Distortion Calculation in Directed Energy Deposition |
| title_sort | inherent strain method using progressive element activation for fast distortion calculation in directed energy deposition |
| topic | inherent strain method simulation finite element analysis directed energy deposition additive manufacturing |
| url | https://www.mdpi.com/2075-4701/14/12/1338 |
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