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PGD model with domain mapping of Bead-on-Plate weld simulation for wire arc additive manufacturing

  • Numerical simulations are essential in predicting the behavior of systems in many engineering fields and industrial sectors. The development of accurate virtual representations of actual physical products or processes allows huge savings in cost and resources. In fact, digital twins would allow reducing the number of real, physical prototypes, tests, and experiments, thus also increasing the sustainability of the production processes and products’ lifetime. Standard numerical methods fail in providing real time simulations, especially for complex processes such as additive manufacturing applications. This work aims to build up a reduced order model for efficient wire arc additive manufacturing simulations by using the proper generalized decomposition (PGD) [1,2] method. Model order reduction is a popular concept to decrease the computational effort, where each evaluation of the reduced forward model is faster than evaluations using classical methods, even for complex models. TheNumerical simulations are essential in predicting the behavior of systems in many engineering fields and industrial sectors. The development of accurate virtual representations of actual physical products or processes allows huge savings in cost and resources. In fact, digital twins would allow reducing the number of real, physical prototypes, tests, and experiments, thus also increasing the sustainability of the production processes and products’ lifetime. Standard numerical methods fail in providing real time simulations, especially for complex processes such as additive manufacturing applications. This work aims to build up a reduced order model for efficient wire arc additive manufacturing simulations by using the proper generalized decomposition (PGD) [1,2] method. Model order reduction is a popular concept to decrease the computational effort, where each evaluation of the reduced forward model is faster than evaluations using classical methods, even for complex models. The simulation of a moving heat source leads to a hardly separable parametric problem, which is solved by a new mapping approach [3]. Using this procedure, it is possible to create a simple separated representation of the forward model. In this contribution, a PGD model is derived for the first part of wire arc additive manufacturing: bead-on-plate weld. An excellent agreement with a standard finite element method is shown. The reduced model is further used in a model calibration set up, speeding up calibrations and ultimately leading to an optimized real-time simulation.zeige mehrzeige weniger

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Metadaten
Autor*innen:Dominic Strobl
Koautor*innen:Annika Robens-Radermacher, C. Ghnatios, Andreas Pittner, Michael Rethmeier, Jörg F. Unger
Dokumenttyp:Vortrag
Veröffentlichungsform:Präsentation
Sprache:Englisch
Jahr der Erstveröffentlichung:2022
Organisationseinheit der BAM:7 Bauwerkssicherheit
7 Bauwerkssicherheit / 7.7 Modellierung und Simulation
9 Komponentensicherheit
9 Komponentensicherheit / 9.3 Schweißtechnische Fertigungsverfahren
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurbau
Freie Schlagwörter:Additive manufacturing; Hardly separable problem; Model calibration; PGD
Themenfelder/Aktivitätsfelder der BAM:Infrastruktur
Veranstaltung:The 8th European Congress on Computational Methods in Applied Sciences and Engineering (ECCOMAS) 2022
Veranstaltungsort:Oslo, Norway
Beginndatum der Veranstaltung:05.06.2022
Enddatum der Veranstaltung:09.06.2022
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:27.06.2022
Referierte Publikation:Nein
Eingeladener Vortrag:Nein
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