Summary
Akshar Kota presented his research at the 20th CIRP Conference on Modelling of Machining Operations (CIRP CMMO 2025) in Mons, Belgium. His work focused on simulating residual stress evolution in Hybrid Wire-Arc Directed Energy Deposition (DED) process that incorporates interlayer machining. This study, now published in Procedia CIRP, highlights the need for improved methods that account for thermo-mechanical effects of machining interventions.
Akshar Kota, a Ph.D. student from our research group, presented his paper titled “Modeling the Residual Stress Evolution in Wire-Arc Directed Energy Deposition with Interlayer Machining Interventions” at the 20th CIRP Conference on Modelling of Machining Operations (CIRP CMMO 2025), held in Mons, Belgium. The research explores the complex problem of predicting residual stresses in Hybrid Wire-Arc DED—a process that integrates Wire-Arc DED with interlayer machining to enhance part geometric accuracy and mechanical performance.
Using Finite Element Analysis, the study models interlayer machining through geometric element deactivation while excluding the thermo-mechanical effects of cutting. The findings reveal that although geometric simplifications provide initial insights, they fall short in fully capturing the residual stress evolution observed experimentally. This work underscores the need for advanced modeling techniques that include machining-induced thermal and mechanical effects to accurately predict and control residual stress in hybrid additive manufacturing processes. The paper is co-authored by Dr. Asif Rashid and Dr. Shreyes N. Melkote and is published in Procedia CIRP. Access the paper here.
