Mathematical modeling the process of wire surfacing by the smoothed particle hydrodynamics method

We discuss issues the process of layer-by-layer synthesis of metal products by wire surfacing. A mathematical model of the process has been developed and implemented. The model allows one to calculate the volumetric distributions of temperatures, melt flow rates, pressures, components of heat fluxes density, the shape and dimensions of the molten bath, the shape of the free surface of the molten metal, the shape and dimensions of the weld bead. For this purpose, the main physical processes that affect the formation of the metal product were considered, namely: melting and crystallization of the metal, surface tension, the Marangoni effect and the heat source features. The smoothed particle method was used to implement this model. A number of numerical experiments were carried out using the developed model. Firstly, the model parameters for steel and titanium were identified and verified. After that, calculations were carried out to verify the model itself using the obtained roller geometry. The numerical solution for the deposition of one layer was compared with the full-scale experiment. The error was no more than 5% in any direction. Thus, the efficiency and correctness of the constructed model is shown. (paper)