Session: 03-08-03: Computational Modeling and Simulation for Advanced Manufacturing

Paper Number: 145556

145556 - Analysing the Influence of Geometry and Tool Paths for a Laser-Based Ded Application 

Introduction: Directed energy deposition (DED) additive manufacturing (AM) layer-based solution approaches have been applied for several technologies and systems. Process planning solutions are being developed for several DED applications. However, comprehensive simulation models that include time-position-layering aspects, which include dwells, need to be developed to explore the influence of tool paths and build geometry on the resulting mechanical and physical properties. Large, detailed simulation models have been developed, generating a comprehensive dataset. Statistically analysing the resulting mechanical and physical properties for select tool path–build geometry is the focus of this research. The goal is to provide insight into effective build strategies for a given component.

Methodology: The finite element method is used to provide toolpath-included processing for the DED fabrications using APlus, a CAD/CAM toolpath generator software, and an element activation/deactivation technique to produce the thermal and mechanical properties of DED-fabricated parts. Selected case studies will be presented for zigzag, transverse, and longitudinal tool paths, with varying levels of geometric complexity, which include:

·         Plate (experimental calibration)

·         Cross

·         Rectangle plate with a rectangular hole

·         3 step plate

·         5 step plate

Global and localized statistical analyses on the stress distributions and distortions are conducted to illustrate the influence of the geometry and toolpaths.

Preliminary results and conclusions: There is no one ideal tool path that is optimal for all geometries. The results show that the stress distribution variance at the last layer is the highest regardless of the geometry and toolpath. The normal distribution of stress indicates that the highest frequency of the stress values (with the highest number of nodes in the same stress region) occur at the same stress range for all layers if no layer-rotation is set for the deposition. The deposition time and the quality of the part have a negative correlation. The toolpath effect is the highest at mid-layers. A regression analysis model suggests that the toolpath effect on the deflection and the maximum stress is higher than the geometry. The cooling time in a multi-track deposition is highly correlated with the part quality.

The novelty and contribution: No rigorous simulations and analyses that associate process planning solution approaches and geometries have been explored in depth. This research needs to be performed to be able to effectively develop effective build solutions and predict model sensitivities for components built using these processes. These solutions will provide a basis for downstream optimization strategies, which include time, material, and strength conditions

Presenting Author: Syamak Pazireh University of Windsor

Presenting Author Biography: Syamak Pazireh is a post-doctoral fellow at the University of Windsor. He is an expert on thermo-mechanical modelling applicable to direct energy deposition manufacturing.

Authors:

Syamak Pazireh University of Windsor
Seyedeh Elnaz Mirazimzadeh University of Windsor
Jill Urbanic University of Windsor
Bob Hedrick CAMufacturing Solutions Inc