A semi-analytical approach to wire arc additive manufacturing simulation for deposition sequence optimisation

ABSTRACT

Categorised as a directed energy deposition process, wire arc additive manufacturing (WAAM) is a promising technology for fabricating large-scale structures and components across various industries. However, the quality of WAAM parts depends on the tool trajectory, as it affects the temperature distribution. Ideally, temperature-related issues, such as overheating, are minimised by choosing an optimal deposition sequence. Selecting the deposition sequence solely on intuition is an unreliable approach, particularly when dealing with complex and irregular parts. This paper introduces a simplified WAAM simulation (SWS) model, which was embedded into an optimisation procedure for determining the optimal deposition sequence of thin-walled WAAM parts. The proposed method is based on a semi-analytical function, which was calibrated and validated using thermal histories obtained from finite element simulations. The findings showed that the proposed SWS model can reproduce the average thermal history at predefined positions within a sample part with minimal computational effort. Moreover, the optimisation successfully identified optimal deposition sequences for producing the sample part regarding a given optimisation criterion. The outcomes of this research contribute to the tool trajectory planning process for WAAM parts. An optimal deposition sequence improves WAAM part quality, increasing the usability of WAAM technology in the production industry.

KEYWORDS:

• Directed energy deposition
• model simplification
• deposition sequence
• tool trajectory
• thermal simulation
• optimisation

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability statement

The data that support the findings of this study are available from the corresponding author, Xiao Fan Zhao, upon reasonable request.

Additional information

Funding

This work was supported by the German Federal Ministry for Economic Affairs and Climate Action (BMWK) [grant number: 13IK002L].