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An Innovative Finite Element Geometric Modeling of Single-Layer Multi-Bead WAAMed Part

Xiangman Zhou1,*, Jingping Qin1, Zichuan Fu1, Min Wang1, Youlu Yuan1, Junjian Fu1, Haiou Zhang2, Seyed Reza Elmi Hosseini3,*

1 College of Mechanical and Power Engineering, China Three Gorges University, Yichang, 443002, China
2 School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
3 School of Metallurgy and Materials Engineering, Iran University of Science and Technology, Narmak, Iran

* Corresponding Authors: Xiangman Zhou. Email: email; Seyed Reza Elmi Hosseini. Email: email

Computer Modeling in Engineering & Sciences 2024, 138(3), 2383-2401. https://doi.org/10.32604/cmes.2023.029249

Abstract

Finite element (FE) coupled thermal-mechanical analysis is widely used to predict the deformation and residual stress of wire arc additive manufacturing (WAAM) parts. In this study, an innovative single-layer multi-bead profile geometric modeling method through the isosceles trapezoid function is proposed to build the FE model of the WAAM process. Firstly, a straight-line model for overlapping beads based on the parabola function was established to calculate the optimal center distance. Then, the isosceles trapezoid-based profile was employed to replace the parabola profiles of the parabola-based overlapping model to establish an innovative isosceles trapezoid-based multi-bead overlapping geometric model. The rationality of the isosceles trapezoid-based overlapping model was confirmed by comparing the geometric deviation and the heat dissipation performance index of the two overlapping models. In addition, the FE-coupled thermal-mechanical analysis, as well as a comparative experiment of the single-layer eight-bead deposition process show that the simulation results of the above two models agree with the experimental results. At the same time, the proposed isosceles trapezoid-based overlapping models are all straight-line profiles, which can be divided into high-quality FE elements. It can improve the modeling efficiency and shorten the simulation calculation time. The innovative modeling method proposed in this study can provide an efficient and high-precision geometric modeling method for WAAM part FE coupled thermal-mechanical analysis.

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APA Style
Zhou, X., Qin, J., Fu, Z., Wang, M., Yuan, Y. et al. (2024). An innovative finite element geometric modeling of single-layer multi-bead waamed part. Computer Modeling in Engineering & Sciences, 138(3), 2383-2401. https://doi.org/10.32604/cmes.2023.029249
Vancouver Style
Zhou X, Qin J, Fu Z, Wang M, Yuan Y, Fu J, et al. An innovative finite element geometric modeling of single-layer multi-bead waamed part. Comput Model Eng Sci. 2024;138(3):2383-2401 https://doi.org/10.32604/cmes.2023.029249
IEEE Style
X. Zhou et al., "An Innovative Finite Element Geometric Modeling of Single-Layer Multi-Bead WAAMed Part," Comput. Model. Eng. Sci., vol. 138, no. 3, pp. 2383-2401. 2024. https://doi.org/10.32604/cmes.2023.029249



cc Copyright © 2024 The Author(s). Published by Tech Science Press.
This work is licensed under a Creative Commons Attribution 4.0 International License , which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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