Residual stress distribution and deformation in wire + arc additive manufactured titanium alloy: insights from simulation and cold cutting analysis

Abstract

The distribution of residual stress and accurate deformation prediction in wire arc additive manufacturing (WAAM) and subsequent cutting components were crucial for practical application. This study focused on simulating titanium alloy walls manufactured by WAAM to analyze thermal and residual stress distributions. Subsequently, the blade shape of the WAAM wall was subjected to cold cutting conditions using the finite element method. The residual stress and deformation of WAAM were studied under various cutting directions. WAAM and cutting components were scanned and analyzed using the Calibry Nest scanner. The findings reveal that in the middle line of the deposition cross-section, residual compressive stress emerges after 18 layers, and the distribution of longitudinal residual stresses follows a "tension–compression-tension" pattern. In cutting direction from the middle to both sides, the deformation of the components is effectively controlled by a narrower residual stress range. As the number of deposition layers increases, the deformation in the width direction rises to a maximum of approximately 0.2 mm. Cold cutting alleviates thermal and residual stresses induced during the WAAM process, reducing substrate deformation.