TY  - EJOU
AU  - Zhou, Xiangman 
AU  - Qin, Jingping 
AU  - Fu, Zichuan 
AU  - Wang, Min 
AU  - Yuan, Youlu 
AU  - Fu, Junjian 
AU  - Zhang, Haiou 
AU  - Hosseini, Seyed Reza Elmi 

TI  - An Innovative Finite Element Geometric Modeling of Single-Layer Multi-Bead WAAMed Part
T2  - Computer Modeling in Engineering \& Sciences

PY  - 2024
VL  - 138
IS  - 3
SN  - 1526-1506

AB  - 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.
KW  - WAAM; FE coupled thermal-mechanical analysis; the isosceles trapezoid-based model; residual stress

DO  - 10.32604/cmes.2023.029249