Goka, Suresh and S, Suryakumar
(2019)
Thermo-Mechanical Analysis and Characterization of Wire Arc
Additive Manufactured Components.
PhD thesis, Indian institute of technology Hyderabad.
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Abstract
Mechanical components are typically isotropic when manufactured by traditional methods such
as casting, forging, etc. However, complex geometries would be difficult with these methods.
In order to fabricate the complex components, various methods have been suggested. One of
such methodsis weld based additive manufacturing wherein welding is used to join the material
selectively at the different locations.
Mechanical tests are usually employed in investigational work in order to obtain information
for use in design and manufacturing to ascertain whether the material meets the specifications
for its intended use, to produce desired mechanical properties like hardness and tensile tests
The intention of performing a simulation or numerical model is to predict the physical
performance of an existing process. On the other hand, it may be essential to compromise the
results in terms of accuracy, computational time of the model. The aim of the current work is
to survey and develop a modeling method to simulate the deposition of a single straight bead
and implementing the same towards constructing thin wall components using the finite element
analysis. The simulating phenomenon is carried out numerically and followed by DFLUX
subroutine. The model must be efficient and reliable enough to be functional in the designing
and path planning of the fabricating features. In addition, a transient thermal distribution of
deposited weld metal is modeled analytically in aspects of various heat sources. Importantly
the heat distribution of the Goldak’s heat source is explored to improve the results of the
experimental analysis. An attempt has been made to correlate the microstructural analysis with
the modeling results. Hence the phase proportion, deformed shape, residual stresses, the
microstructural analysis could be evaluated.
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