ABSTRACT Components distort during directed energy deposition (DED) additive manufacturing (AM) due to the repeated localised heating. Changing the geometry in such a way that distortion causes it to assume the desired shape – a technique called distortion-compensation – is a promising method to reach geometrically accurate parts. Transient numerical simulation can be used to generate the compensated geometries and severely reduce the amount of necessary experimental trials. This publication demonstrates the simulation-based generation of a distortion-compensated DED build for an industrial-scale component. A transient thermo-mechanical approach is extended for large parts and the accuracy is demonstrated against 3d-scans. The calculated distortions are inverted to derive the compensated geometry and the distortions after a single compensation iteration are reduced by over 65%.

中文翻译：

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通过瞬态数值模拟进行定向能量沉积增材制造的几何畸变补偿

摘要 在定向能量沉积 (DED) 增材制造 (AM) 过程中，由于重复的局部加热，组件会变形。以扭曲导致其呈现所需形状的方式更改几何形状 - 一种称为扭曲补偿的技术 - 是获得几何精确零件的有前途的方法。瞬态数值模拟可用于生成补偿几何形状并大大减少必要的实验次数。该出版物演示了基于仿真的失真补偿 DED 构建，用于工业规模组件。瞬态热机械方法扩展到大型零件，并通过 3d 扫描证明了准确性。