Advanced Search
CHEN Shujun, NI Qingmian, LIU Haibin, CHEN Pingping, YAN Chaoyang, XIE Ruishan. Numerical simulation of hybrid additive and subtractive manufacturing and evolution behavior of stress and deformation[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2025, 46(5): 1-9. DOI: 10.12073/j.hjxb.20240131002
Citation: CHEN Shujun, NI Qingmian, LIU Haibin, CHEN Pingping, YAN Chaoyang, XIE Ruishan. Numerical simulation of hybrid additive and subtractive manufacturing and evolution behavior of stress and deformation[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2025, 46(5): 1-9. DOI: 10.12073/j.hjxb.20240131002

Numerical simulation of hybrid additive and subtractive manufacturing and evolution behavior of stress and deformation

More Information
  • Received Date: January 30, 2024
  • Available Online: May 05, 2025
  • The final forming accuracy of additive manufacturing components depends not only on the stress accumulation and deformation during the additive manufacturing process, but also on the stress release and redistribution during milling.Therefore, a joint simulation method of hybrid additive and subtractive manufacturing was established, and the stress accumulation behavior in the process of additive manufacturing and its stress release and secondary deformation law in the subsequent material removal process were expounded. The results show that, in the process of arc additive manufacturing, there is a three-dimensional tensile stress at the interface between the part and the substrate in the first few layers and the final cooling stage. In the process of milling additive manufacturing, the residual stress is gradually released and redistributed, and the position of the maximum residual stress changes and the tensile stress decreases. At the same time, in the process of milling, the part undergoes secondary deformation, with large deformation at both ends and small deformation in the middle. The joint simulation method of hybrid additive and subtractive manufacturing proposed in this paper provides theoretical guidance for the deformation control of the final formed part.

  • [1]
    SONG Y A, PARK S, CHOI D, et al. 3D welding and milling : Part I - a direct approach for freeform fabrication of metallic prototypes[J]. International Journal of Machine Tools and Manufacture, 2005, 45(9): 1057-1062.
    [2]
    KARUNAKARAN K P, SURYAKUMAR S, PUSHPA V, et al. Low cost integration of additive and subtractive processes for hybrid layered manufacturing[J]. Robotics and Computer-Integrated Manufacturing, 2010, 26(5): 490 − 499.
    [3]
    SADEGHIFAR M, JAVIDIKIA M, LOUCIF A, et al. Experimental and numerical analyses of residual stress redistributions in large steel dies: Influence of tempering cycles and rough milling[J]. Journal of Materials Research and Technology, 2023, 24: 395 − 406. doi: 10.1016/j.jmrt.2023.03.044
    [4]
    GE G, XIAO Y, FENG X, et al. An efficient prediction method for the dynamic deformation of thin-walled parts in flank milling[J]. Computer-Aided Design, 2022, 152: 103401. doi: 10.1016/j.cad.2022.103401
    [5]
    XIE R, CHEN G, ZHAO Y, et al. In-situ observation and numerical simulation on the transient strain and distortion prediction during additive manufacturing[J]. Journal of Manufacturing Processes, 2019, 38: 494 − 501. doi: 10.1016/j.jmapro.2019.01.049
    [6]
    XIE R, SHI Q , CHEN G. Improved distortion prediction in additive manufacturing using an experimental-based stress relaxation model[J]. Journal of Materials Science & Technology, 2020, 59: 83 − 91.
    [7]
    韩文涛, 林健, 雷永平, 等. 不同层间停留时间下电弧增材制造2Cr13薄壁件热力学行为[J]. 焊接学报, 2019, 40(12): 47 − 52.

    HAN Wentao, LIN Jian, LEI Yongping, et al. Thermodynamic behavior of 2Cr13 thin-walled components in arc additive manufacturing under different inter-layer dwell times[J]. Transactions of the China Welding Institution, 2019, 40(12): 47 − 52.
    [8]
    DING J, COLEGROVE P, MEHNEN J, et al. Thermo-mechanical analysis of wire and arc additive layer manufacturing process on large multi-layer parts[J]. Computational Materials Science, 2011, 50(12): 3315 − 3322. doi: 10.1016/j.commatsci.2011.06.023
    [9]
    DENLINGER E R, MICHALERIS P. Mitigation of distortion in large additive manufacturing parts[J]. Proceedings of the Institution of Mechanical Engineers Part B-Journal of Enginee, 2017, 231(6): 983 − 993. doi: 10.1177/0954405415578580
    [10]
    SUN J, HENSEL J, KöHLER M, et al. Residual stress in wire and arc additively manufactured aluminum components[J]. Journal of Manufacturing Processes, 2021, 65: 97 − 111. doi: 10.1016/j.jmapro.2021.02.021
    [11]
    HUANG W, WANG Q, MA N, et al. Distribution characteristics of residual stresses in typical wall and pipe components built by wire arc additive manufacturing[J]. Journal of Manufacturing Processes, 2022, 82: 434 − 447. doi: 10.1016/j.jmapro.2022.08.010
    [12]
    LINDGREN L E. Numerical modelling of welding[J]. Computer Methods in Applied Mechanics and Engineering, 2006, 195(48): 6710 − 6736.
    [13]
    XIE R, ZHAO Y, CHEN G, et al. Development of efficient distortion prediction numerical method for laser additive manufactured parts[J]. Journal of Laser Applications, 2019, 31(2):022314.
    [14]
    HODGE N E, FERENCZ R M , SOLBERG J M. Implementation of a thermomechanical model for the simulation of selective laser melting[J]. Computational Mechanics, 2014, 54(1): 33 − 51.
    [15]
    HEIGEL J C, MICHALERIS P, REUTZEL E W. Thermo-mechanical model development and validation of directed energy deposition additive manufacturing of Ti–6Al–4V[J]. Additive Manufacturing, 2015, 5: 9 − 19. doi: 10.1016/j.addma.2014.10.003
    [16]
    SALONITIS K, D'ALVISE L, SCHOINOCHORITIS B, et al. Additive manufacturing and post-processing simulation: laser cladding followed by high speed machining[J]. International Journal of Advanced Manufacturing, 2016, 85(9-12): 2401 − 2411. doi: 10.1007/s00170-015-7989-y
    [17]
    赵宇辉, 高孟秋, 赵吉宾, 等. 基于有限元模型的增减材一体化复合制造技术热力耦合研究[J]. 机械工程学报, 2022, 58(15): 274 − 282. doi: 10.3901/JME.2022.15.274

    ZHAO Yuhui, GAO Mengqiu, ZHAO Jibin, et al. Study on thermo mechanical coupling of the hybrid additive and subtractive manufacturing based on finite element model[J]. Journal of Mechanical Engineering, 2022, 58(15): 274 − 282. doi: 10.3901/JME.2022.15.274
    [18]
    SUNNY S, MATHEWS R, GLEASON G, et al. Effect of metal additive manufacturing residual stress on post-process machining-induced stress and distortion[J]. International Journal of Mechanical Sciences, 2021, 202-203: 106534. doi: 10.1016/j.ijmecsci.2021.106534
    [19]
    WEBER D, KIRSCH B, CHIGHIZOLA C R, et al. Investigation on the scale effects of initial bulk and machining induced residual stresses of thin walled milled monolithic aluminum workpieces on part distortions: experiments and finite element prediction model[J]. Procedia CIRP, 2021, 102: 337 − 342. doi: 10.1016/j.procir.2021.09.058
    [20]
    LANDWEHR M, SCHMID S, HOLLA V, et al. The finite cell method for the prediction of machining distortion caused by initial residual stresses in milling[J]. Procedia CIRP, 2021, 102: 144 − 149. doi: 10.1016/j.procir.2021.09.025
    [21]
    ALIPOORAMIRABAD H, PARADOWSKA A, GHOMASHCHI R, et al. Investigating the effects of welding process on residual stresses, microstructure and mechanical properties in HSLA steel welds[J]. Journal of Manufacturing Processes, 2017, 28: 70 − 81. doi: 10.1016/j.jmapro.2017.04.030
    [22]
    陈健, 吕林, 方锴. 超声冲击改善6061铝合金焊接残余应力的数值模拟[J]. 焊接学报, 2013, 34(12): 88 − 92.

    CHEN Jian, LYU Lin, FANG Kai. Numerical simulation of ultrasonic impact on improving welding residual stress in 6061 aluminum alloy[J]. Transactions of the China Welding Institution, 2013, 34(12): 88 − 92.
    [23]
    LU X, LIN X, CHIUMENTI M, et al. Finite element analysis and experimental validation of the thermomechanical behavior in laser solid forming of Ti-6Al-4V[J]. Additive Manufacturing, 2018, 21: 30 − 40. doi: 10.1016/j.addma.2018.02.003
    [24]
    王海龙,王素娟. 6061铝合金超精密切削仿真与实验研究[J]. 机械设计与制造, 2023(7): 147 − 150.

    WANG Hailong, WANG Sujuan. Simulation and experimental study of ultra-precision cutting of 6061 aluminum alloy[J]. Machinery Design & Manufacture, 2023(7): 147 − 150.
  • Related Articles

    [1]SHEN Faming, CUI Yanfeng, SHAO Tongge, LI Yongjun, HAN Yonghua, LI Rui, YANG Guang. Tailored deformation and properties of cast aluminum alloy ZL114A repaired by laser deposition[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2024, 45(8): 121-128. DOI: 10.12073/j.hjxb.20230506001
    [2]Guobin ZHANG, Meng JIANG, Xi CHEN, Ao CHEN, Zhenglong LEI, Yanbin CHEN. A comparison study of characteristics of weld formation, residual stress and distortion of laser welding under atmospheric pressure and vacuum[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2022, 43(8): 34-41. DOI: 10.12073/j.hjxb.20220503002
    [3]SUN Hongyu, ZHOU Qi, ZHU Jun, SHI Xiaodong, SUN Zhiming. Analysis on deformation of friction stir welding joint of thin aluminum alloy[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2019, 40(11): 155-160. DOI: 10.12073/j.hjxb.2019400303
    [4]HAN Tao, GU Shiwei, XU Liang, ZHANG Hongjie, OUYANG Kai. Study on stress and deformation of K-TIG welded joint[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2019, 40(11): 125-132. DOI: 10.12073/j.hjxb.2019400299
    [5]XU Hailaing, GUO Xingye, LEI Yongping, LIN Jian, XIAO Rongshi. Residual stress and deformation of ultra-thin 316 stainless steel plate using pulsed laser welding process[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2019, 40(8): 50-54. DOI: 10.12073/j.hjxb.2019400208
    [6]CAI Jianpeng, SUN Jiamin, XIA Linyin, Deng Dean. Prediction on welding residual stress and deformation in Q345 steel butt-welded joints[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2015, 36(11): 61-64,68.
    [7]ZHU Hao, GUO Zhu, CUI Shaopeng, WANG Yanhong. Deformation behaviors and equivalent model of TIG welded joint of 6063 aluminum alloy[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2014, 35(7): 67-71.
    [8]JIANG Wenchun, ZHANG Yucai, GUAN Xuewei. Thermal stress and deformation in bonded compliant seal design for planar SOFC[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2012, (11): 55-58.
    [9]WANG Yanfei, GENG Luyang, GONG Jianming, JIANG Wenchun. Numerical analysis to study effect of turn number on residual stress and deformation of butt welded 20MnMoNb super-thick tube-sheet[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2012, (10): 13-16,24.
    [10]XU Ji-jin, CHEN Li-gong, NI Chun-zhen. Temperature distribution,deformation and residual stresses of thick plate butt multipass welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2006, (5): 97-100.

Catalog

    Article views (110) PDF downloads (33) Cited by()

    /

    DownLoad:  Full-Size Img  PowerPoint
    Return
    Return