Modelling and optimising hybrid process of wire arc additive manufacturing and high-pressure rolling

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dc.contributor.authorGornyakov, Valeriy
dc.contributor.authorSun, Yongle
dc.contributor.authorDing, Jialuo
dc.contributor.authorWilliams, Stewart
dc.date.accessioned2022-10-03T13:06:41Z
dc.date.available2022-10-03T13:06:41Z
dc.date.issued2022-09-22
dc.description.abstractHybrid process of wire arc additive manufacturing (WAAM) and high-pressure rolling can build large-scale components with low detrimental residual stress (RS) and distortion. We developed an efficient coupled process model for a steel wall to simulate the interaction between WAAM deposition and rolling. The predicted RS distributions and wall dimensions agree well with experimental results. Cyclic variation of longitudinal tensile RS occurs during WAAM deposition and inter-layer rolling in clamped condition. The influence depth of deposition and rolling is characterised by the number of the underlying layers that are plastically deformed after each process cycle. For the inter-layer rolling with a flat roller, the rolling has smaller influence depth than the deposition; consequently, the rolling does not eliminate but rather contains the regeneration of WAAM tensile RS after thermal cycles. Rolling with a slotted roller introduces more tensile plastic strain and thereby more effectively reduces WAAM tensile RS and unclamping distortion. Compared to the inter-layer rolling, stacked-four-layer rolling has larger influence depth and hence achieves similar RS mitigation efficacy with fewer rolling operations, while post-build rolling has lower efficacy due to insufficient penetration. Therefore, stacked-layers rolling with slotted roller is recommended for an optimal hybrid process of WAAM and rolling.en_UK
dc.identifier.citationGornyakov V, Sun Y, Ding J, Williams S. (2022) Modelling and optimising hybrid process of wire arc additive manufacturing and high-pressure rolling. Materials and Design, Volume 223, November 2022, Article number 111121en_UK
dc.identifier.issn0264-1275
dc.identifier.urihttps://doi.org/10.1016/j.matdes.2022.111121
dc.identifier.urihttps://dspace.lib.cranfield.ac.uk/handle/1826/18506
dc.language.isoenen_UK
dc.publisherElsevieren_UK
dc.rightsAttribution 4.0 International*
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/*
dc.subjectDirected energy depositionen_UK
dc.subjectCold workingen_UK
dc.subjectResidual stressen_UK
dc.subjectDistortionen_UK
dc.subjectNumerical simulationen_UK
dc.titleModelling and optimising hybrid process of wire arc additive manufacturing and high-pressure rollingen_UK
dc.typeArticleen_UK

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