Three-Dimensional Finite Element Analysis with Clamping in Wire and Arc Additive Manufacturing

Clamping is necessary to reduce distortion and defect in wire and arc additive manufacturing. Considering the clamping model in simulation can improve the prediction accuracy of the distortion and residual stress. In this paper, a three-dimensional finite element model with corner clamping is established, and the weld-bead profile and heat source model is verified with experimental result. Using the Simufact.welding finite element analysis software, total distortion, effective residual stress distribution as well as the stress components are investigated. It has been observed that the maximum effective stress distributes in the region near clamping from beginning to end. The effective stress of the middle point along the transversal side is the side minimum stress, while there is a stress peak in the longitudinal side middle point owing to the distortion reduction during cooling time. The clamping form has a significant relationship with total distortion and residual stress distribution. According to the stress components analysis, the transversal stress is much higher than longitudinal stress, and plays a dominant role in the residual stress.