Modelling wire-arc-additive manufacturing for joining by forming applications
This work examines material deposition through wire-arc additive manufacturing (WAAM) to create functional elements on conventional wrought sheets, which are subsequently plastically deformed using conventional metal forming operations. The investigation employed finite element modelling to address...
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| Format: | Article |
| Language: | English |
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EDP Sciences
2025-01-01
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| Series: | MATEC Web of Conferences |
| Subjects: | |
| Online Access: | https://www.matec-conferences.org/articles/matecconf/pdf/2025/02/matecconf_iddrg2025_02022.pdf |
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| _version_ | 1850152208929128448 |
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| author | Viegas João M. A. Rosado Pedro M. S. Sampaio Rui F. V. Pragana João P. M. Bragança Ivo M. F. Silva Carlos M. A. Martins Paulo A. F. |
| author_facet | Viegas João M. A. Rosado Pedro M. S. Sampaio Rui F. V. Pragana João P. M. Bragança Ivo M. F. Silva Carlos M. A. Martins Paulo A. F. |
| author_sort | Viegas João M. A. |
| collection | DOAJ |
| description | This work examines material deposition through wire-arc additive manufacturing (WAAM) to create functional elements on conventional wrought sheets, which are subsequently plastically deformed using conventional metal forming operations. The investigation employed finite element modelling to address material nonlinearities caused by heating and cooling cycles during the layer-by-layer material deposition process and accounted for the interchangeable boundary conditions caused by the newly activated mesh elements triggered by the moving heat source and the geometric nonlinearities resulting from thermal-induced distortions during material deposition and unclamping. Experiments were carried out to produce the features and measure the resulting distortion of the final parts using two different clamping systems. An application is provided in which the features are utilized to create rivets for fabricating form-closed mechanical interlocks in hybrid electrical busbar joints. This example demonstrates the usefulness of new hybrid manufacturing routes combining wire-arc additive manufacturing with metal forming for joining by forming applications. |
| format | Article |
| id | doaj-art-524f312f6a1249d7bcfc3095e741d74b |
| institution | OA Journals |
| issn | 2261-236X |
| language | English |
| publishDate | 2025-01-01 |
| publisher | EDP Sciences |
| record_format | Article |
| series | MATEC Web of Conferences |
| spelling | doaj-art-524f312f6a1249d7bcfc3095e741d74b2025-08-20T02:26:02ZengEDP SciencesMATEC Web of Conferences2261-236X2025-01-014080202210.1051/matecconf/202540802022matecconf_iddrg2025_02022Modelling wire-arc-additive manufacturing for joining by forming applicationsViegas João M. A.0Rosado Pedro M. S.1Sampaio Rui F. V.2Pragana João P. M.3Bragança Ivo M. F.4Silva Carlos M. A.5Martins Paulo A. F.6IDMEC, Instituto Superior Técnico, Universidade de LisboaIDMEC, Instituto Superior Técnico, Universidade de LisboaIDMEC, Instituto Superior Técnico, Universidade de LisboaIDMEC, Instituto Superior Técnico, Universidade de LisboaCIMOSM, Instituto Superior de Engenharia de Lisboa, Instituto Politécnico de LisboaIDMEC, Instituto Superior Técnico, Universidade de LisboaIDMEC, Instituto Superior Técnico, Universidade de LisboaThis work examines material deposition through wire-arc additive manufacturing (WAAM) to create functional elements on conventional wrought sheets, which are subsequently plastically deformed using conventional metal forming operations. The investigation employed finite element modelling to address material nonlinearities caused by heating and cooling cycles during the layer-by-layer material deposition process and accounted for the interchangeable boundary conditions caused by the newly activated mesh elements triggered by the moving heat source and the geometric nonlinearities resulting from thermal-induced distortions during material deposition and unclamping. Experiments were carried out to produce the features and measure the resulting distortion of the final parts using two different clamping systems. An application is provided in which the features are utilized to create rivets for fabricating form-closed mechanical interlocks in hybrid electrical busbar joints. This example demonstrates the usefulness of new hybrid manufacturing routes combining wire-arc additive manufacturing with metal forming for joining by forming applications.https://www.matec-conferences.org/articles/matecconf/pdf/2025/02/matecconf_iddrg2025_02022.pdfwire-arc additive manufacturingfinite elementsexperimentationhybrid manufacturing |
| spellingShingle | Viegas João M. A. Rosado Pedro M. S. Sampaio Rui F. V. Pragana João P. M. Bragança Ivo M. F. Silva Carlos M. A. Martins Paulo A. F. Modelling wire-arc-additive manufacturing for joining by forming applications MATEC Web of Conferences wire-arc additive manufacturing finite elements experimentation hybrid manufacturing |
| title | Modelling wire-arc-additive manufacturing for joining by forming applications |
| title_full | Modelling wire-arc-additive manufacturing for joining by forming applications |
| title_fullStr | Modelling wire-arc-additive manufacturing for joining by forming applications |
| title_full_unstemmed | Modelling wire-arc-additive manufacturing for joining by forming applications |
| title_short | Modelling wire-arc-additive manufacturing for joining by forming applications |
| title_sort | modelling wire arc additive manufacturing for joining by forming applications |
| topic | wire-arc additive manufacturing finite elements experimentation hybrid manufacturing |
| url | https://www.matec-conferences.org/articles/matecconf/pdf/2025/02/matecconf_iddrg2025_02022.pdf |
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