Analytical Model for Distortion Prediction in Wire + Arc Additive Manufacturing

Analytical Model for Distortion Prediction in Wire + Arc Additive Manufacturing

J.R. Hönnige, P. Colegrove, S. Williams

Abstract. An analytical model was developed to predict bending distortion of the base-plate caused by residual stresses in additively manufactured metal deposits. This avoids time-consuming numerical simulations for a fast estimation of the expected distortion. Distortion is the product of the geometry factor K, which is determined by the cross-section of substrate and deposit, and the material and process factor S, which is the quotient of residual stress and the Young’s Modulus. A critical wall height can be calculated for which the structure distorts the most. This critical height is typically less than 2.5 times the thickness of the substrate. Higher walls increase the stiffness of the cross-section and reduce the distortion with increasing height.

Keywords
Residual Stress, Bending Distortion, Neutron Diffraction, Geometry Factor, Material and Process Factor, Critical Wall Height

Published online 9/11/2018, 6 pages
Copyright © 2018 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: J.R. Hönnige, P. Colegrove, S. Williams, ‘Analytical Model for Distortion Prediction in Wire + Arc Additive Manufacturing’, Materials Research Proceedings, Vol. 6, pp 277-282, 2018

DOI: https://dx.doi.org/10.21741/9781945291890-44

The article was published as article 44 of the book Residual Stresses 2018

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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