SIM-AM 2023

Reduced Order Model with Domain Mapping for Temperature Field Simulation of Wire Arc Additive Manufacturing

  • Strobl, Dominic (Bundesanstalt für Materialforschung und -prüf)
  • Robens-Radermacher, Annika (Bundesanstalt für Materialforschung und -prüf)
  • Ghnatios, Chady (PIMM Laboratory, HESAM University)
  • Pittner, Andreas (Bundesanstalt für Materialforschung und -prüf)
  • Rethmeier, Michael (IWF, Technische Universität Berlin)
  • Unger, Jörg F (Bundesanstalt für Materialforschung und -prüf)

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Additive manufacturing (AM) has revolutionized the manufacturing industry, offering a new paradigm to produce complex geometries and parts with customized properties. Among the different AM techniques, the wire arc additive manufacturing (WAAM) process has gained significant attention due to its high deposition rate and low equipment cost. However, the process is characterized by a complex thermal history, dynamic metallurgy, and mechanical behaviour that make it challenging to simulate it in real-time for online process control and optimization. In this context, a reduced order model (ROM) using the proper generalized decomposition (PGD) method [1] is proposed as a powerful tool to overcome the limitations of conventional numerical methods and enable the real-time simulation of the temperature field of WAAM processes. Though, the simulation of a moving heat source leads to a hardly separable parametric problem, which is handled by applying a novel mapping approach [2]. Using this procedure, it is possible to create a simple separated representation of the model, also allowing to simulate multiple layers. In this contribution, a PGD model is derived for the WAAM procedure simulating the temperature field. A good agreement with a standard finite element method is shown. The reduced model is further used in a stochastic model parameter estimation using Bayesian inference, speeding up calibrations and ultimately leading to a calibrated real-time simulation.