University of Twente Student Theses


Design and validation of clamping system for Wire and Arc Additive Manufacturing

Veugelers, Manuel (2018) Design and validation of clamping system for Wire and Arc Additive Manufacturing.

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Abstract:Wire and Arc Additive Manufacturing (WAAM) is an upcoming additive layer manufacturing technology that uses an electric plasma arc as heat source to melt and deposit wire-fed metallic material. High deposition rates and cost effectiveness make this technology a promising alternative to conventional machining. Today, one of the main challenges is the residual thermal stress causing distortions in the final product. An innovative clamping system has been designed to mitigate these distortions. A fully coupled thermo-mechanical finite element method (FEM) analysis is carried out to gain insight in the process and material behaviour, and to determine the occurring reaction forces in a simply constrained test set-up. These results, in combination with a static structural FEM analysis of the developed concept, resulted in a dimensioned clamping system. Based on force calculations and integration in the design, a suitable actuator is chosen for the system. Validating analyses showed that the system behaves as expected and can withstand the loads that occur during the process. From this, an expandable modular clamping system is proposed, which is developed for a test set-up, but is applicable in the general case. Practical tests need to be performed to further validate the solution, which are planned to be carried out at the WAAM set-up at Tecnalia. However, these tests fall outside the scope of this report.
Item Type:Internship Report (Master)
Faculty:ET: Engineering Technology
Subject:52 mechanical engineering
Programme:Mechanical Engineering MSc (60439)
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