Prediction of residual stresses induced by any additive layer manufacturing process greatly helps in preventing thermal cracking and distortion formed in the substrate and deposition material. This paper presents the development of a model for the prediction of residual stresses using three-dimensional finite element simulation (3D-FES) and their experimental validation in a single-track and double-track deposition of Ti-6Al-4V powder on AISI 4130 substrate by the microplasma transferred arc (µ-PTA) powder deposition process. It involved 3D-FES of the temperature distribution and thermal cycles that were validated experimentally using three K-type thermocouples mounted along the deposition direction. Temperature distribution, thermal cycles, and residual stresses are predicted in terms of the µ-PTA process parameters and temperature-dependent properties of substrate and deposition materials. Influence of a number of deposition tracks on the residual stresses is also studied. Results reveal that (i) tensile residual stress is higher at the bonding between the deposition and substrate and attains a minimum value at the midpoint of a deposition track; (ii) maximum tensile residual stress occurs in the substrate material at its interface with deposition track. This primarily causes distortion and thermal cracks; (iii) maximum compressive residual stress occurs approximately at mid-height of the substrate material; and (iv) deposition of a subsequent track relieves tensile residual stress induced by the previously deposited track.
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June 2019
Research-Article
Modeling and Prediction of Residual Stresses in Additive Layer Manufacturing by Microplasma Transferred Arc Process Using Finite Element Simulation
Sagar H. Nikam,
Sagar H. Nikam
Discipline of Mechanical and Manufacturing Engineering,
School of Computing, Engineering and Intelligent Systems,
Derry/Londonderry BT48 7JL,
Northern Ireland,
e-mail: s.nikam@ulster.ac.uk
School of Computing, Engineering and Intelligent Systems,
Ulster University
,Derry/Londonderry BT48 7JL,
Northern Ireland,
UK
e-mail: s.nikam@ulster.ac.uk
Search for other works by this author on:
N. K. Jain
N. K. Jain
Professor
Discipline of Mechanical Engineering,
Simrol 453 552,
Madhya Pradesh,
e-mail: nkjain@iiti.ac.in
Discipline of Mechanical Engineering,
Indian Institute of Technology Indore
,Simrol 453 552,
Madhya Pradesh,
India
e-mail: nkjain@iiti.ac.in
Search for other works by this author on:
Sagar H. Nikam
Discipline of Mechanical and Manufacturing Engineering,
School of Computing, Engineering and Intelligent Systems,
Derry/Londonderry BT48 7JL,
Northern Ireland,
e-mail: s.nikam@ulster.ac.uk
School of Computing, Engineering and Intelligent Systems,
Ulster University
,Derry/Londonderry BT48 7JL,
Northern Ireland,
UK
e-mail: s.nikam@ulster.ac.uk
N. K. Jain
Professor
Discipline of Mechanical Engineering,
Simrol 453 552,
Madhya Pradesh,
e-mail: nkjain@iiti.ac.in
Discipline of Mechanical Engineering,
Indian Institute of Technology Indore
,Simrol 453 552,
Madhya Pradesh,
India
e-mail: nkjain@iiti.ac.in
Manuscript received May 28, 2018; final manuscript received March 19, 2019; published online April 12, 2019. Assoc. Editor: Qiang Huang.
J. Manuf. Sci. Eng. Jun 2019, 141(6): 061003 (14 pages)
Published Online: April 12, 2019
Article history
Received:
May 28, 2018
Revision Received:
March 19, 2019
Accepted:
March 19, 2019
Citation
Nikam, S. H., and Jain, N. K. (April 12, 2019). "Modeling and Prediction of Residual Stresses in Additive Layer Manufacturing by Microplasma Transferred Arc Process Using Finite Element Simulation." ASME. J. Manuf. Sci. Eng. June 2019; 141(6): 061003. https://doi.org/10.1115/1.4043264
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