Fatigue lifetime estimation of Wire Arc Additive Manufactured (WAAM) component using full process chaining simulation
This research focuses on understanding and estimating the effects of residual stresses induced by Wire Arc Additive Manufacturing (WAAM) technique and subsequent corrective machining process on fatigue/fretting fatigue lifetime. To do so, a finite element toolkit will be developed to chain together several manufacturing processes to achieve a final finished product, following the fatigue/fretting fatigue lifetime estimation of the final product. To do so, the developed finite element code chains together the following processes (i) construction of a piece by WAAM, (ii) stress-relief heat treatment, (iii) corrective machining to obtain the finished piece with the desired dimensions, surface quality, low residual stresses and (iv) estimating fatigue/fretting fatigue lifetime of the final product. The developed numerical toolkit will be used to perform parametric study and find the best processing parameters which lead to improvement of components subjected to fatigue/fretting fatigue loading conditions. The proposed full process chaining simulation allows the designers to improve the design of final product by modifying the process parameters.