Laser directed energy deposition (LDED) is a unique 3D printing technology, which has capability to produce fully dense materials components with high deposition rate. Additive manufacturing has opened a totally new perspective for the engineering field with new opportunities and challenges, especially in fields like aerospace, defence, energy, medical, etc., where there is a need for high customization and great necessity for cost reduction. When it comes to the repairing of components belonging to these fields, the laser-based Directed Energy Deposition (DED) process is highly advantageous due to its precise control over key variables, facilitating the fulfilment of stringent requirements in diverse fields. The present work has been done with modelling and simulation with optimized bead profile by using thermal mechanical model to capture the deformations more accurately, temperature distribution, and measure of the residual stresses and to test the profile considered for modelling and compare the simulation results with the practical set-up and to validate the output to confirm the modelling approach. And thus, the modelling set-up can be used for further simulations to validate overlapping beads in multiple tracks and to determine the thermal histories and cycles. In the present work, at different power the residual stresses and deformation are measured and validated with the experimental result considering rectangular and parabolic bead profile of the layers. The result shows that parabolic bead profile gives good result as compared to rectangular bead profile.

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Three-Dimensional Numerical Simulation of Laser Metal Deposition Method with Bead Profile Optimization

  • Jay Chandra Maurya,
  • A. S. V. Nagarjuna,
  • Manjaiah Mallaiah

摘要

Laser directed energy deposition (LDED) is a unique 3D printing technology, which has capability to produce fully dense materials components with high deposition rate. Additive manufacturing has opened a totally new perspective for the engineering field with new opportunities and challenges, especially in fields like aerospace, defence, energy, medical, etc., where there is a need for high customization and great necessity for cost reduction. When it comes to the repairing of components belonging to these fields, the laser-based Directed Energy Deposition (DED) process is highly advantageous due to its precise control over key variables, facilitating the fulfilment of stringent requirements in diverse fields. The present work has been done with modelling and simulation with optimized bead profile by using thermal mechanical model to capture the deformations more accurately, temperature distribution, and measure of the residual stresses and to test the profile considered for modelling and compare the simulation results with the practical set-up and to validate the output to confirm the modelling approach. And thus, the modelling set-up can be used for further simulations to validate overlapping beads in multiple tracks and to determine the thermal histories and cycles. In the present work, at different power the residual stresses and deformation are measured and validated with the experimental result considering rectangular and parabolic bead profile of the layers. The result shows that parabolic bead profile gives good result as compared to rectangular bead profile.