Details
| Original language | English |
|---|---|
| Pages (from-to) | 655-677 |
| Number of pages | 23 |
| Journal | Computational Particle Mechanics |
| Volume | 7 |
| Issue number | 4 |
| Early online date | 30 Nov 2019 |
| Publication status | Published - Jul 2020 |
Abstract
In selective laser melting (SLM), three-dimensional parts are build up from a metal powder bed by layer-wise melting with a laser. While SLM offers a high flexibility in geometrical design and material texture, the interplay of dozens of parameters is difficult to analyze experimentally. The current research focuses on numerical simulation to increase confidence in manufactured parts and to reduce the time to market. Using a smoothed particle hydrodynamics (SPH) implementation on GPU, the 3D melt pool dynamics in a single laser track can be simulated within less than 2 h with a reasonable spatial resolution of 3 μ m. This is an extreme speedup compared to concurrent CFD methods that have recently been applied to the same problem. Using a SPH implementation on GPU, the 3D melt pool dynamics in a single laser track can be simulated within less than an hour with a reasonable spatial resolution of 3 μ m. This is an extreme speedup compared to concurrent CFD methods that have recently been applied to the same problem. The computational efficiency allows to conduct parameter studies, which before were prohibitively expensive, to generate a virtual process. To make the simulations possible a curvature calculation technique was applied, which is novel in the field of SPH. Additionally the advantage of a direct description of the internal energy is outlined by comparing the approach with the commonly applied apparent heat approach. Designers may profit from the fast simulations in two different scenarios: firstly, through a direct numerical simulation of certain parameter combinations and scenarios and, secondly, by informing advanced surrogate models or part-scale models to predict the behavior of the entire part being produced. When adapting the heat source model, the SPH framework may also be used to describe the related electron beam melting process.
Keywords
- Additive manufacturing, Laser powder bed fusion, Selective laser melting, SPH, Steel powder, Surface tension, Virtual process map
ASJC Scopus subject areas
- Engineering(all)
- Computational Mechanics
- Engineering(all)
- Civil and Structural Engineering
- Mathematics(all)
- Numerical Analysis
- Mathematics(all)
- Modelling and Simulation
- Chemical Engineering(all)
- Fluid Flow and Transfer Processes
- Mathematics(all)
- Computational Mathematics
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In: Computational Particle Mechanics, Vol. 7, No. 4, 07.2020, p. 655-677.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Generating virtual process maps of SLM using powder-scale SPH simulations
AU - Fürstenau, Jan Philipp
AU - Wessels, Henning
AU - Weißenfels, Christian
AU - Wriggers, Peter
PY - 2020/7
Y1 - 2020/7
N2 - In selective laser melting (SLM), three-dimensional parts are build up from a metal powder bed by layer-wise melting with a laser. While SLM offers a high flexibility in geometrical design and material texture, the interplay of dozens of parameters is difficult to analyze experimentally. The current research focuses on numerical simulation to increase confidence in manufactured parts and to reduce the time to market. Using a smoothed particle hydrodynamics (SPH) implementation on GPU, the 3D melt pool dynamics in a single laser track can be simulated within less than 2 h with a reasonable spatial resolution of 3 μ m. This is an extreme speedup compared to concurrent CFD methods that have recently been applied to the same problem. Using a SPH implementation on GPU, the 3D melt pool dynamics in a single laser track can be simulated within less than an hour with a reasonable spatial resolution of 3 μ m. This is an extreme speedup compared to concurrent CFD methods that have recently been applied to the same problem. The computational efficiency allows to conduct parameter studies, which before were prohibitively expensive, to generate a virtual process. To make the simulations possible a curvature calculation technique was applied, which is novel in the field of SPH. Additionally the advantage of a direct description of the internal energy is outlined by comparing the approach with the commonly applied apparent heat approach. Designers may profit from the fast simulations in two different scenarios: firstly, through a direct numerical simulation of certain parameter combinations and scenarios and, secondly, by informing advanced surrogate models or part-scale models to predict the behavior of the entire part being produced. When adapting the heat source model, the SPH framework may also be used to describe the related electron beam melting process.
AB - In selective laser melting (SLM), three-dimensional parts are build up from a metal powder bed by layer-wise melting with a laser. While SLM offers a high flexibility in geometrical design and material texture, the interplay of dozens of parameters is difficult to analyze experimentally. The current research focuses on numerical simulation to increase confidence in manufactured parts and to reduce the time to market. Using a smoothed particle hydrodynamics (SPH) implementation on GPU, the 3D melt pool dynamics in a single laser track can be simulated within less than 2 h with a reasonable spatial resolution of 3 μ m. This is an extreme speedup compared to concurrent CFD methods that have recently been applied to the same problem. Using a SPH implementation on GPU, the 3D melt pool dynamics in a single laser track can be simulated within less than an hour with a reasonable spatial resolution of 3 μ m. This is an extreme speedup compared to concurrent CFD methods that have recently been applied to the same problem. The computational efficiency allows to conduct parameter studies, which before were prohibitively expensive, to generate a virtual process. To make the simulations possible a curvature calculation technique was applied, which is novel in the field of SPH. Additionally the advantage of a direct description of the internal energy is outlined by comparing the approach with the commonly applied apparent heat approach. Designers may profit from the fast simulations in two different scenarios: firstly, through a direct numerical simulation of certain parameter combinations and scenarios and, secondly, by informing advanced surrogate models or part-scale models to predict the behavior of the entire part being produced. When adapting the heat source model, the SPH framework may also be used to describe the related electron beam melting process.
KW - Additive manufacturing
KW - Laser powder bed fusion
KW - Selective laser melting
KW - SPH
KW - Steel powder
KW - Surface tension
KW - Virtual process map
UR - http://www.scopus.com/inward/record.url?scp=85076105547&partnerID=8YFLogxK
U2 - 10.1007/s40571-019-00296-3
DO - 10.1007/s40571-019-00296-3
M3 - Article
AN - SCOPUS:85076105547
VL - 7
SP - 655
EP - 677
JO - Computational Particle Mechanics
JF - Computational Particle Mechanics
SN - 2196-4378
IS - 4
ER -