Efficient prediction of residual stress in additive manufacturing based on semi-analytical solution

In order to improve the efficiency of residual stress simulation in laser powder feeding additive manufacturing, a finite element modeling method that only requires to solve the stress field is proposed and established in this paper. First, the analytical solution of the heat conduction equation is simplified, and a new temperature field model is developed, which can be directly input into the stress field model for calculation, thereby eliminating the calculation of the temperature field in the thermal-mechanical coupling simulation process and improving the simulation efficiency of residual stress in additive manufacturing. On this basis, the effectiveness of the method is verified by a single-pass single-layer cladding simulation. Meanwhile, the residual stress of single-pass multi-layer cladding is calculated and compared with the measured results, and the distribution characteristics of residual stress in additive manufacturing are studied. It is demonstrated that the result of the established model is closed to that of thermal-mechanical coupled finite element method. The established model can reflect the residual stress of laser powder feeding additive manufacturing process. Compared with the traditional thermal-mechanical coupled finite element method, the computational efficiency of the model established in this study is greatly improved.