Robi, Mathews
(2013)
Effect of Area-Filling Path on the Residual Stresses Developed During Weld-Deposition Based Additive Manufacturing.
Masters thesis, Indian Institute of Technology Hyderabad.
Abstract
There is an increasing interest in the industry for using Additive Manufacturing
techniques not just for prototyping but for actual applications too. For this to
happen, various constraints in commercialization of the metallic components made
by using additive manufacturing have to be overcome. Management of thermally
induced residual stresses during the deposition of metal is one of the major
challenges that need to be addressed. With the help of numerical and experimental
methods, this paper studies effect of area filling paths on the residual stresses
developed during weld-deposition. Finite element analysis is done using ANSYS
Mechanical APDL for different area filling paths. The temperature gradient and the
thermally induced residual stress produced during material deposition are predicted
using finite element analysis. The obtained results were validated with the help of
experiments. A GMAW welding system was attached to the CNC to create the
desired area filling pattern. The residual stresses were measured using a XRD
system. The process parameters used in the finite element study and experiments
were based on initial trials carried out to determine the operatable range of
parameters. Three area-filling patterns viz., zig-zag, contour (outside-in) and contour
(inside-out) were analyzed; maximum residual stress concentration was found to
occur in the case of contour (outside-in).
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