TY - JOUR A1 - Strobl, Dominic A1 - Unger, Jörg F. A1 - Ghnatios, C. A1 - Klawoon, Alexander A1 - Pittner, Andreas A1 - Rethmeier, Michael A1 - Robens-Radermacher, Annika T1 - Efficient bead-on-plate weld model for parameter estimation towards effective wire arc additive manufacturing simulation N2 - Despite the advances in hardware and software techniques, standard numerical methods fail in providing real-time simulations, especially for complex processes such as additive manufacturing applications. A real-time simulation enables process control through the combination of process monitoring and automated feedback, which increases the flexibility and quality of a process. Typically, before producing a whole additive manufacturing structure, a simplified experiment in the form of a beadon-plate experiment is performed to get a first insight into the process and to set parameters suitably. In this work, a reduced order model for the transient thermal problem of the bead-on-plate weld simulation is developed, allowing an efficient model calibration and control of the process. The proposed approach applies the proper generalized decomposition (PGD) method, a popular model order reduction technique, to decrease the computational effort of each model evaluation required multiple times in parameter estimation, control, and optimization. The welding torch is modeled by a moving heat source, which leads to difficulties separating space and time, a key ingredient in PGD simulations. A novel approach for separating space and time is applied and extended to 3D problems allowing the derivation of an efficient separated representation of the temperature. The results are verified against a standard finite element model showing excellent agreement. The reduced order model is also leveraged in a Bayesian model parameter estimation setup, speeding up calibrations and ultimately leading to an optimized real-time simulation approach for welding experiment using synthetic as well as real measurement data. KW - Proper generalized decomposition KW - Model order reduction KW - Hardly separable problem KW - Additive manufacturing KW - Model calibration KW - Wire arc additive manufacturing PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-596502 DO - https://doi.org/10.1007/s40194-024-01700-0 SN - 0043-2288 SP - 1 EP - 18 PB - Springer AN - OPUS4-59650 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Robens-Radermacher, Annika T1 - Temperature dependent modelling approach for early age behavior of printable mortars N2 - For extrusion-based 3D concrete printing, the early age mechanical behavior is influenced by various time dependent phenomena: structural build-up, plasticity as well as viscosity. The structural build-up is governing the stability and early-age strength development of the fresh printable cementitious materials and with that influencing the printability, buildability, and open time of the printing process. Generally, it is influenced by a number of factors, i.e. composition of the printable material, printing regime, and ambient conditions (temperature, humidity, etc.). There are several approaches to model the structural build-up of cementitious materials. All models are based on a time-dependent internal structural parameter describing the flocculation state, which is assumed to be zero after mixing and increases with time. The approaches differ in the definition of the time dependency (linear, exponential, bi-linear). Usually, the parameters are defined for a specific material composition without considering the influence of ambient conditions. In this contribution, the bi-linear structural build-up model [Kruger et al., Construction and Building Materials 224, 2019] is extended by the temperature influence. Temperature changes will occur in real life printing processes due to changing ambient conditions (summer, winter, day, night) as well as the printing process (pressure changes etc.) and have a significant impact on the structural build-up process: an increase of the temperature leads to a faster dissolution of cement phases, accelerates hydration and boosts the Brownian motion. For that reason, the model parameters are simulated as temperature dependent using an Arrhenius function. Furthermore, the proposed extended model is calibrated based on measurement data using Bayesian inference. A very good agreement of the predicted model data with the measured control data was reached. Additionally, the structural build-up model is integrated into a viscoelastic and elastoplastic mechanical model, simulating the whole mechanical behavior during layer deposition. T2 - Eighth International Symposium on Life-Cycle Civil Engineering (IALCCE 2023) CY - Milan, Italy DA - 03.07.2023 KW - 3D concrete printing KW - Material characterization KW - Structural build-up KW - Thixotropy KW - Model calibration PY - 2023 AN - OPUS4-58218 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Robens-Radermacher, Annika A1 - Unger, Jörg F. A1 - Mezhov, Alexander A1 - Schmidt, Wolfram ED - Biondini, F. ED - Frangopo, D. M. T1 - Temperature dependent modelling approach for early age behavior of printable mortars N2 - Structural build-up describes the stability and early-age strength development of fresh mortar used in 3D printing. lt is influenced by several factors, i.e. the composition of the print­ able material, the printing regime, and the ambient conditions. The existing modelling approaches for structural build-up usually define the model parameters for a specific material composition with­ out considering the influence of the ambient conditions. The goal of this contribution is to explicitly include the temperature dependency in the modelling approach. Temperature changes have signifi­ cant impact on the structural build-up process: an increase of the temperature leads to a faster dissol­ ution of cement phases and accelerates hydration. The proposed extended model includes temperature dependency using the Arrhenius theory. The new model parameters are successfully calibrated based on Viskomat measurement data using Bayesian inference. Furthermore, a higher impact of the temperature in the re-flocculation as in the structuration stage is observed. T2 - The Eighth International Symposium on Life-Cycle Civil Engineering (IALCCE 2023) CY - Milano, Italien DA - 02.07.2023 KW - 3D concrete printing KW - Material characterization KW - Structural build-up KW - Thixotropy KW - Model calibration PY - 2023 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-582175 SN - 978-1-003-32302-0 DO - https://doi.org/10.1201/9781003323020-146 SN - 978-1-003-32302-0 VL - 1st Edition SP - 1193 EP - 1200 PB - CRC Press AN - OPUS4-58217 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -