Numerical simulation process parameter optimization in metal additive manufacturing for getting better quality of products

Wire Arc Additive Manufacturing (WAAM) is used to produces small to large components because of its high accuracy in deposition rate and potentially unlimited build size. As online simulation has become an important tool nowadays, encouragement of using online tools for wire arc additive manufacturing has changed the wide picture. In this experiment, numerical simulation is done in software to find the better quality of product and also processed it in real time to match the optimum values. In this study the input parameters considered are velocity, laser power and the Colling time and better quality is found out by varying these values in the range found out using maximum and minimum tolerable limits. The output parameters which were considered were displacement and von misses stress and then better-quality values were derived. After getting simulated values from software numerical simulation was done in Design Expert software and predicted values were taken and compared to simulated values from software. Then using RSM with central composite design approach 20 runs were done and the predicted graph were taken we the optimised value was found. After those final results were conducted in Altair software, Real-time and optimized values were verified. (c) 2022 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Thermal Analysis and Energy Systems 2021.