Wire arc additive manufacturing simulator based on Vatti clipping

This study develops a shape calculation-based simulator for Wire Arc Additive Manufacturing (WAAM). To improve forming precision and reduce the extensive trial- and-error process in AM, the simulator employs an expanded Vatti clipping algorithm capable of handling arcs and the Axis-Aligned Bounding Box (AABB) method for rapid and precise Boolean operations between 2D polygons. The simulator models bead shapes as ellipsoids based on 3D measurement data from actual WAAM processed workpieces. Experiments conducted with various feed rates of the welding wire and torch unit validate the accuracy of the identified model. It is shown that the simulator has demonstrated sufficient precision for multi-layer forming. A case study of the formation of a turbine blade-like structure confirmed the effectiveness of the developed simulator, despite minor discrepancies in height due to cumulative identification errors. Although the bead drop effect in large overhanging parts has not yet been implemented, the developed simulator shows potential as an effective tool for simulating WAAM processes.