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Real-time Bead-on-Plate weld Simulation for Wire Arc Additive Manufacturing using Reduced Order modelling coupled with stochastic model Calibration

  • 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 (also known as digital twins) 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 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 use a reduced order model for efficient wire arc additive manufacturing simulations, calibrations and real-time process control. Model reduction, e.g. the proper generalized decomposition [1,2] method, is a popular concept to decrease the computational effort. A new mapping approach [3] was applied to simulate a moving heat source with 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 (also known as digital twins) 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 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 use a reduced order model for efficient wire arc additive manufacturing simulations, calibrations and real-time process control. Model reduction, e.g. the proper generalized decomposition [1,2] method, is a popular concept to decrease the computational effort. A new mapping approach [3] was applied to simulate a moving heat source with the proper generalized decomposition. Using this procedure even complex models can be simulated in real-time. The physical model is later on calibrated with the use of a stochastic model updating process and the reduced order model, leading to an optimized real-time simulation. In this contribution, a proper generalized decomposition model for a bead-on-plate wire arc additive manufacturing is presented. It is also coupled with a stochastic model updating process identifying the heat source characteristics as well as the boundary conditions of the transient thermal problem, whereas the heat source shape is simulated using a Goldak heat sourcezeige 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 / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Model calibration; Reduced order modelling; Wire arc additive manufacturing
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Additive Fertigung
Veranstaltung:15th World Congress on Computational Mechanics (WCCM-XV)
Veranstaltungsort:Yokohama, Japan
Beginndatum der Veranstaltung:31.07.2022
Enddatum der Veranstaltung:05.08.2022
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:26.08.2022
Referierte Publikation:Nein
Eingeladener Vortrag:Nein
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