Development of a calibration technique of a finite element model for calculating compensation of deformations from the action of residual stresses in additive manufacturing

Abstract

In additive manufacturing, it is necessary to take into account and compensate for the warping of the part due to the action of residual stresses. One of the effective fast methods for calculating the magnitude of deformations in CAE-systems is mechanical finite element analysis, which does not require numerous iterations. To ensure the accuracy of calculations in CAE-systems, they must be calibrated on special samples. The paper proposes a method of such calibration on annular samples for the process of direct metal deposition (DMD), the result of which are the values of internal deformations necessary to calculate the deformations of parts during DMD. With the help of the Simufact Additive CAE system, a digital model of the DMD process was designed and the effect of residual stresses was simulated. Based on the obtained results of comparison with full-scale samples, the calculated parameters have been adjusted, which can be applied to optimize the geometry of the workpiece parts, taking into account the features of the DMD process.