Prediction of residual strain/stress validated with neutron diffraction method for wire-feed hybrid additive/subtractive manufacturing

Yousub Lee; Thomas Feldhausen; Chris M. Fancher; Peeyush Nandwana; Sudarsanam S. Babu; Srdjan Simunovic; Lonnie J. Love

doi:10.1016/j.addma.2023.103920

Prediction of residual strain/stress validated with neutron diffraction method for wire-feed hybrid additive/subtractive manufacturing

Yousub Lee, Thomas Feldhausen, Chris M. Fancher, Peeyush Nandwana, Sudarsanam S. Babu, Srdjan Simunovic, Lonnie J. Love

Research output: Contribution to journal › Article › peer-review

14 Scopus citations

Abstract

Hybrid manufacturing integrates additive manufacturing (AM) and subtractive manufacturing in the same machine. The integration of the two processes enables the creation of complex geometry, further reduces material waste, and decreases lead time. Moreover, this in-envelop method enables an interleaved printing strategy in which the part is partially AM printed and then machined repeatedly. This method is not available in either traditional manufacturing or AM technologies. Nevertheless, measuring and controlling of distortion and residual stress are still challenging due to highly varying process conditions and limited access to the machine during hybrid additive/subtractive manufacturing processes. Moreover, the residual stress measurement is ex-situ process, so it only gives information at the final stage of stress evolution. Therefore, it's nearly impossible to know the AM induced residual stress distribution before the machining process in hybrid additive/subtractive process. In this prospective, numerical modeling can be an effective tools to overcome those challenges. However, the modelling/simulation methods for fully-coupled additive and subtractive operation has not reported to the best of our knowledge. In this work, we developed a comprehensive simulation method using finite element method (FEM) for fully-coupled additive and subtractive manufacturing process. The results were validated with strain measurements by neutron diffraction in two different machining conditions: hot-machining and cold-machining. The validated model was used to investigate how machining affects part distortion and evolution of residual strain/stress during fabrication. Alternating tensile-compression longitudinal (ε₁₁, x-direction) strains and stresses along the build direction showed the physical interaction of additive and subtractive steps in the interleaved strategy. The alternating pattern was found in both the model and neutron diffraction measurements. This work's findings can be used to develop strategies to control of part distortion and residual stresses in the hybrid additive/subtractive manufacturing process.

Original language	English
Article number	103920
Journal	Additive Manufacturing
Volume	79
DOIs	https://doi.org/10.1016/j.addma.2023.103920
State	Published - Jan 5 2024

Funding

This manuscript has been supported by the America Makes and Air Force Research Laboratory (AFRL) under contract number 2243-Z423–21 and by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office (AMMTO) under contract number DE-AC05–00OR22725. The authors thank Dr. Guru Madireddy for helping with data generation, and Dr. Kyle Saleeby, Mr. Dennis Brown, Mr. Matthew Sallas and Dr. Brian Post at ORNL. Notice of Copyright. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05–00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). This manuscript has been supported by the America Makes and Air Force Research Laboratory (AFRL) under contract number 2243-Z423–21 and by the US Department of Energy , Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office ( AMMTO ) under contract number DE-AC05–00OR22725 . The authors thank Dr. Guru Madireddy for helping with data generation, and Dr. Kyle Saleeby, Mr. Dennis Brown, Mr. Matthew Sallas and Dr. Brian Post at ORNL.

Keywords

Finite Element Method
Hybrid Additive/Subtractive Manufacturing
Interleaved Printing Strategy
Neutron Diffraction
Residual Strains/Stresses

Access to Document

10.1016/j.addma.2023.103920

Cite this

@article{4f0c6437bcbf434d9d6e86d9c9ad6f7b,

title = "Prediction of residual strain/stress validated with neutron diffraction method for wire-feed hybrid additive/subtractive manufacturing",

abstract = "Hybrid manufacturing integrates additive manufacturing (AM) and subtractive manufacturing in the same machine. The integration of the two processes enables the creation of complex geometry, further reduces material waste, and decreases lead time. Moreover, this in-envelop method enables an interleaved printing strategy in which the part is partially AM printed and then machined repeatedly. This method is not available in either traditional manufacturing or AM technologies. Nevertheless, measuring and controlling of distortion and residual stress are still challenging due to highly varying process conditions and limited access to the machine during hybrid additive/subtractive manufacturing processes. Moreover, the residual stress measurement is ex-situ process, so it only gives information at the final stage of stress evolution. Therefore, it's nearly impossible to know the AM induced residual stress distribution before the machining process in hybrid additive/subtractive process. In this prospective, numerical modeling can be an effective tools to overcome those challenges. However, the modelling/simulation methods for fully-coupled additive and subtractive operation has not reported to the best of our knowledge. In this work, we developed a comprehensive simulation method using finite element method (FEM) for fully-coupled additive and subtractive manufacturing process. The results were validated with strain measurements by neutron diffraction in two different machining conditions: hot-machining and cold-machining. The validated model was used to investigate how machining affects part distortion and evolution of residual strain/stress during fabrication. Alternating tensile-compression longitudinal (ε11, x-direction) strains and stresses along the build direction showed the physical interaction of additive and subtractive steps in the interleaved strategy. The alternating pattern was found in both the model and neutron diffraction measurements. This work's findings can be used to develop strategies to control of part distortion and residual stresses in the hybrid additive/subtractive manufacturing process.",

keywords = "Finite Element Method, Hybrid Additive/Subtractive Manufacturing, Interleaved Printing Strategy, Neutron Diffraction, Residual Strains/Stresses",

author = "Yousub Lee and Thomas Feldhausen and Fancher, {Chris M.} and Peeyush Nandwana and Babu, {Sudarsanam S.} and Srdjan Simunovic and Love, {Lonnie J.}",

note = "Publisher Copyright: {\textcopyright} 2023 The Authors",

year = "2024",

month = jan,

day = "5",

doi = "10.1016/j.addma.2023.103920",

language = "English",

volume = "79",

journal = "Additive Manufacturing",

issn = "2214-8604",

publisher = "Elsevier",

}

TY - JOUR

T1 - Prediction of residual strain/stress validated with neutron diffraction method for wire-feed hybrid additive/subtractive manufacturing

AU - Lee, Yousub

AU - Feldhausen, Thomas

AU - Fancher, Chris M.

AU - Nandwana, Peeyush

AU - Babu, Sudarsanam S.

AU - Simunovic, Srdjan

AU - Love, Lonnie J.

PY - 2024/1/5

Y1 - 2024/1/5

N2 - Hybrid manufacturing integrates additive manufacturing (AM) and subtractive manufacturing in the same machine. The integration of the two processes enables the creation of complex geometry, further reduces material waste, and decreases lead time. Moreover, this in-envelop method enables an interleaved printing strategy in which the part is partially AM printed and then machined repeatedly. This method is not available in either traditional manufacturing or AM technologies. Nevertheless, measuring and controlling of distortion and residual stress are still challenging due to highly varying process conditions and limited access to the machine during hybrid additive/subtractive manufacturing processes. Moreover, the residual stress measurement is ex-situ process, so it only gives information at the final stage of stress evolution. Therefore, it's nearly impossible to know the AM induced residual stress distribution before the machining process in hybrid additive/subtractive process. In this prospective, numerical modeling can be an effective tools to overcome those challenges. However, the modelling/simulation methods for fully-coupled additive and subtractive operation has not reported to the best of our knowledge. In this work, we developed a comprehensive simulation method using finite element method (FEM) for fully-coupled additive and subtractive manufacturing process. The results were validated with strain measurements by neutron diffraction in two different machining conditions: hot-machining and cold-machining. The validated model was used to investigate how machining affects part distortion and evolution of residual strain/stress during fabrication. Alternating tensile-compression longitudinal (ε11, x-direction) strains and stresses along the build direction showed the physical interaction of additive and subtractive steps in the interleaved strategy. The alternating pattern was found in both the model and neutron diffraction measurements. This work's findings can be used to develop strategies to control of part distortion and residual stresses in the hybrid additive/subtractive manufacturing process.

AB - Hybrid manufacturing integrates additive manufacturing (AM) and subtractive manufacturing in the same machine. The integration of the two processes enables the creation of complex geometry, further reduces material waste, and decreases lead time. Moreover, this in-envelop method enables an interleaved printing strategy in which the part is partially AM printed and then machined repeatedly. This method is not available in either traditional manufacturing or AM technologies. Nevertheless, measuring and controlling of distortion and residual stress are still challenging due to highly varying process conditions and limited access to the machine during hybrid additive/subtractive manufacturing processes. Moreover, the residual stress measurement is ex-situ process, so it only gives information at the final stage of stress evolution. Therefore, it's nearly impossible to know the AM induced residual stress distribution before the machining process in hybrid additive/subtractive process. In this prospective, numerical modeling can be an effective tools to overcome those challenges. However, the modelling/simulation methods for fully-coupled additive and subtractive operation has not reported to the best of our knowledge. In this work, we developed a comprehensive simulation method using finite element method (FEM) for fully-coupled additive and subtractive manufacturing process. The results were validated with strain measurements by neutron diffraction in two different machining conditions: hot-machining and cold-machining. The validated model was used to investigate how machining affects part distortion and evolution of residual strain/stress during fabrication. Alternating tensile-compression longitudinal (ε11, x-direction) strains and stresses along the build direction showed the physical interaction of additive and subtractive steps in the interleaved strategy. The alternating pattern was found in both the model and neutron diffraction measurements. This work's findings can be used to develop strategies to control of part distortion and residual stresses in the hybrid additive/subtractive manufacturing process.

KW - Finite Element Method

KW - Hybrid Additive/Subtractive Manufacturing

KW - Interleaved Printing Strategy

KW - Neutron Diffraction

KW - Residual Strains/Stresses

UR - http://www.scopus.com/inward/record.url?scp=85180737793&partnerID=8YFLogxK

U2 - 10.1016/j.addma.2023.103920

DO - 10.1016/j.addma.2023.103920

M3 - Article

AN - SCOPUS:85180737793

SN - 2214-8604

VL - 79

JO - Additive Manufacturing

JF - Additive Manufacturing

M1 - 103920

ER -

Prediction of residual strain/stress validated with neutron diffraction method for wire-feed hybrid additive/subtractive manufacturing

Abstract

Funding

Keywords

Access to Document

Other files and links

Fingerprint

Cite this