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Efficient bead-on-plate weld model for parameter estimation towards effective wire arc additive manufacturing simulation

  • 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 flexibil- ity and quality of a process. Typically, before producing a whole additive manufacturing structure, a simplified experiment in form of a bead-on- 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 devel- oped, 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 timesDespite 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 flexibil- ity and quality of a process. Typically, before producing a whole additive manufacturing structure, a simplified experiment in form of a bead-on- 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 devel- oped, 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 tem- perature. 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.zeige mehrzeige weniger

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Metadaten
Autor*innen:Dominic Strobl, Jörg F. Unger, G. Chady, Alexander Klawoon, Andreas Pittner, Michael Rethmeier, Annika Robens-Radermacher
Dokumenttyp:Forschungsdatensatz
Veröffentlichungsform:Graue Literatur
Sprache:Englisch
Jahr der Erstveröffentlichung:2023
Organisationseinheit der BAM:7 Bauwerkssicherheit
7 Bauwerkssicherheit / 7.7 Modellierung und Simulation
Herausgeber (Institution):Bundesanstalt für Materialforschung und -prüfung (BAM)
Verlag:Zenodo
Verlagsort:Geneva
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Ermüdung
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Additive Fertigung
Art der Ressource:Software
Ort der Datenerhebung:Berlin, Germany
Beginndatum der Datenerstellung:19.12.2022
Enddatum der Datenerstellung:31.12.2023
DOI:10.5281/zenodo.7456813
Verfügbarkeit des Dokuments:Datei für die Öffentlichkeit verfügbar ("Open Access")
Lizenz (Deutsch):License LogoCreative Commons - CC BY - Namensnennung 4.0 International
Datum der Freischaltung:14.03.2024
Referierte Publikation:Nein
Schriftenreihen ohne Nummerierung:Forschungsdatensätze der BAM
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