Learning Forum

[Jonas S]

Hello,

as part of my bachelor's thesis, I am focusing on the Ansys additive suite. More specifically, I am examining the simulation of the Wire Arc Additive Manufacturing (WAAM) process (Directed Energy Deposition - DED process simulation). As far as I can tell, the process simulation in Mechanical (Workbench) provides insight only into the stresses that occur in the part after the cooling process is done. The challenges of the process itself, such as the formation of the melt pool, the feasibility of overhangs, and sagging, do not appear to be calculated here.

I have read that in the standalone application "Additive (Print / Science)" the process can be simulated in a way that allows for the optimization of process parameters and the representation of the imperfect real geometry with individual layers. However, I wonder if "Additive (Print / Science)" exclusively includes the simulation of powder bed-based processes, or if it can also simulate the DED process (WAAM)?

Thank you in advance

Jonas 

 

[John Doyle]

As you know, the goal of Additive simulations, in WB-Mechanical interface, is to predict the macro-level distortions and stresses in parts to prevent build failures and provide trend data for improving designs for additive manufacturing including part orientation and support placement and sizing. This interface supports both LPBF and DED simulations. The simulation is not meant to provide detailed thermal or structural results needed for prediction of micro-level process phenomena (that is, microstructure). Please refer to the Additive Manufacturing LPBF and DED guides for more details of the methodology and underlying assumptions.

Our complementary offering, Additive Science, is a separate tool used to obtain information about the melt pool characteristics on the microstructure level.  However, it is set up to follow the industry practice of testing single beads on PBF machines, in which the laser runs in one single scan line across a powder deposition layer.  Since there is no powder deposition layer in a DED process, I am not sure how well the Additive Science simulation would translate to a DED process. 

[Jonas S]

Thank you for the quick reply. 
Is there (in the Additive (Print / Science) application) the possibility to adjust the simulation manually (similar to the APDL in Mechanical)?
Or does Additive exist as a ready-made solution that cannot / should not be edited?