Numerical modelling of heat transfer and experimental validation in powder-bed fusion with the virtual domain approximation
Among metal additive manufacturing technologies, powder-bed fusion features very thin layers and rapid solidification rates, leading to long build jobs and a highly localized process. Many efforts are being devoted to accelerate simulation times for practical industrial applications. The new approac...
| Autores: | , , , , , , , , , |
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| Tipo de recurso: | artículo |
| Fecha de publicación: | 2019 |
| País: | España |
| Institución: | Universitat Politècnica de Catalunya (UPC) |
| Repositorio: | UPCommons. Portal del coneixement obert de la UPC |
| Idioma: | inglés |
| OAI Identifier: | oai:upcommons.upc.edu:2117/172674 |
| Acceso en línea: | https://hdl.handle.net/2117/172674 https://dx.doi.org/10.1016/j.finel.2019.103343 |
| Access Level: | acceso abierto |
| Palabra clave: | Manufacturing processes--Mathematical models Additive Manufacturing (AM) Powder-bed fusion (PBF) Selective laser melting (SLM) Finite elements (FE) Thermal Analysis High performance computing (HPC) Fabricació -- Models matemàtics Àrees temàtiques de la UPC::Enginyeria dels materials::Metal·lúrgia Àrees temàtiques de la UPC::Matemàtiques i estadística::Anàlisi numèrica::Mètodes en elements finits |
| Sumario: | Among metal additive manufacturing technologies, powder-bed fusion features very thin layers and rapid solidification rates, leading to long build jobs and a highly localized process. Many efforts are being devoted to accelerate simulation times for practical industrial applications. The new approach suggested here, the virtual domain approximation, is a physics-based rationale for spatial reduction of the domain in the thermal finite-element analysis at the part scale. Computational experiments address, among others, validation against a large physical experiment of 17.5[cm3]of deposited volume in 647 layers. For fast and automatic parameter estimation at such level of complexity, a high-performance computing framework is employed. It couples FEMPAR-AM,a specialized parallel finite-element software, with Dakota, for the parametric exploration. Compared to previous state-of-the-art, this formulation provides higher accuracy at the same computational cost. This sets the path to a fully virtualized model, considering an upwards-moving domain covering the last printed layers. |
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