<p class="MsoNormal">Wire-arc additive manufacturing (WAAM) using Gas Metal Arc Welding (GMAW) has been integrated into a machine tool to create a retrofit hybrid computer numeric control (CNC) machine tool. GMAW, along with other direct energy deposition systems, has the capacity to deposit material faster than the excess thermal energy can dissipate. One of the most time-consuming processes during the additive process is waiting for the part to cool so consecutive layers can be deposited. Finite element analysis (FEA) with ANSYS was used in conjunction with monitored surface temperatures during a deposition to improve adequate dwell time prediction and to develop a cooling system. A deposition was completed where no dwell time was used and the build plate along with the machine table temperatures were monitored. A second deposition was completed where only one bead was deposited and the traverse speed was increased. A GMAW welder was mounted on a 3-axis CNC machine where two square deposition samples were completed. The first deposition was two beads wide completed with a traverse speed of 16 inches per minute, 2.5-millimeter layer height, and 30 second dwells. The second deposition was a single bead completed with a traverse speed of 19.2 inches per minute, 2.1-millimeter layer height, and no dwells. A FEA model was designed and verified using the monitored samples. The model will be used to determine maximum depositions speeds and whether forced cooling would allow for an increased deposition rate without structural failure.</p>

Prediction of Thermal Conditions of Ded With Fea Metal Additive Simulation

Paper Proceedings: https://asmedigitalcollection.asme.org/MSEC/MSEC2021/volume/85062

2021 International Manufacturing Science and Engineering Conference (MSEC2021)

Supporting the need among researchers worldwide for additional online and multimedia content, ASME now offers the ASME Conference Video Collection. This platform will collect and provide long-term access to conference presentation videos, encompassing all technology areas within ASME's technical conference and events program. About 30,000-40,000 engineers across all mechanical engineering and related disciplines participate in ASME conferences each year. This includes authors of approximately 6,000 to 8,000 technical papers published by ASME, the majority of whom also submit video presentations for our virtual conferences. The video collection will be available as an add-on to existing product packages or as a separate subscription.