An Automated Deposition Procedure for Cold Spray Additive Manufacturing Process Modeling Based on Finite Element Simulation

摘要

The present paper presents modeling of the Cold Spraying Process using a progressive build-up technique. This technique is based on the modeling features dedicated to the Additive Manufacturing Process. It has the major advantage in saving computational cost while maintaining reasonable numerical accuracy compared to other finite element solutions that involve realistic impact simulations for thousands of particles. The new approach uses the database obtained from one-time finite element simulations performed with the Eulerian scheme by computing the corresponding thermomechanical fields averaged over a gauge length. This is inserted into the progressive build-up model with a pair of subroutines for the definition of initial stresses and equivalent plastic strains. The material addition has been performed in the finite element analysis by progressively activating the elements that take the values of the averaged thermomechanical fields at the moment of activation. To undergo element activation, another pair of subroutines are used to locate the elements that are within a sphere of a fixed radius and belonging to the deposition toolpath or segment. The deposition segments considered in the modeling are an event series presenting the element status with respect to the tool coordinates and time. The deposition input parameters have been specified using a table collection. The progressive build-up procedure has been used to determine the thermomechanical fields such as temperature in the coating and residual stress in the structure.