Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components

High pressure multi-layer rolling is an effective method to reduce residual stress and distortion in metallic components built by wire arc additive manufacturing (WAAM). However, the mechanisms of reduction during are not well understood. Conventional finite element models for highly inefficient, hindering simulation large WAAM components. This study aims identify most suitable modelling technique analysis component rolling. Four efficient were developed, their efficiency accuracy compared with reference a conventional large-scale model (i.e., control model) wall. A short-length transient fewer elements than was developed computational time. Accurate predictions strain time 96.5% achieved using when implicit numerical solution employed, while similar but less accurate prediction obtained explicit adopted. Eulerian steady-state also which slightly (95.91% time) much due unrealistic representation process. The applicability 2D examined it found that (99.52% reduction) predictive simplification. shows rigid roller adopted beneficial improving without sacrificing accuracy.