A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processes

This work presents an h-adaptive finite-element (FE) strategy to address the numerical simulation of additive manufacturing (AM) of large-scale parts. The wire-arc additive manufacturing is chosen as the demonstrative technology for its manufacturing capabilities suitable for industrial purposes. Th...

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Autores: Filho, Carlos Augusto Moreira|||0000-0003-4605-6301, Caicedo Silva, Manuel Alejandro|||0000-0001-7300-799X, Cervera Ruiz, Miguel|||0000-0003-3437-6703, Chiumenti, Michele|||0000-0002-6286-7393, Baiges Aznar, Joan|||0000-0002-3940-5887
Tipo de documento: artigo
Data de publicação:2022
País:España
Recursos:Universitat Politècnica de Catalunya (UPC)
Repositório:UPCommons. Portal del coneixement obert de la UPC
Idioma:inglês
OAI Identifier:oai:upcommons.upc.edu:2117/377663
Acesso em linha:https://hdl.handle.net/2117/377663
https://dx.doi.org/10.1007/s00366-022-01655-0
Access Level:Acceso aberto
Palavra-chave:Manufacturing processes--Mathematical models
Finite elements
Multi-criteria adaptive mesh refinement
Additive manufacturing
GCode-based simulation
Hierarchical octree-based meshes
Fabricació -- Models matemàtics
Àrees temàtiques de la UPC::Enginyeria dels materials
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repository_id_str
spelling A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processesFilho, Carlos Augusto Moreira|||0000-0003-4605-6301Caicedo Silva, Manuel Alejandro|||0000-0001-7300-799XCervera Ruiz, Miguel|||0000-0003-3437-6703Chiumenti, Michele|||0000-0002-6286-7393Baiges Aznar, Joan|||0000-0002-3940-5887Manufacturing processes--Mathematical modelsFinite elementsMulti-criteria adaptive mesh refinementAdditive manufacturingGCode-based simulationHierarchical octree-based meshesFabricació -- Models matemàticsÀrees temàtiques de la UPC::Enginyeria dels materialsThis work presents an h-adaptive finite-element (FE) strategy to address the numerical simulation of additive manufacturing (AM) of large-scale parts. The wire-arc additive manufacturing is chosen as the demonstrative technology for its manufacturing capabilities suitable for industrial purposes. The scanning path and processing parameters of the simulation are provided via a RS-274 (GCode) file, being the same as the one delivered to the AM machine. The approach is suitable for industrial applications and can be applied to other AM processes. To identify the location in the FE mesh of the heat affected zone (HAZ), a collision detection algorithm based on the separating axis theorem is used. The mesh is continuously adapted to guarantee the necessary mesh resolution to capture the phenomena inside and outside the HAZ. To do so, a multi-criteria adaptive mesh refinement and coarsening (AMR) strategy is used. The AMR includes a geometrical criterion to guarantee the FE size within the HAZ, and a Zienkiewicz–Zhu-based a-posteriori error estimator to guarantee the solution accuracy elsewhere. Thus, the number of active FEs is controlled and mesh manipulation by the end-user is avoided. Numerical simulations comparing the h-adaptive strategy with the (reference) fixed fine meshes are performed to prove the computational cost efficiency and the solution accuracy.The financial support from the Spanish Ministry of Economy and Competitiveness, through the Severo Ochoa Programme for Centres of Excellence in R&D (CEX2018-000797-S), is gratefully acknowledged. This work has been supported by the European Union’s horizon 2020 research and innovation programme (H2020-DT-2019-1 no. 872570) under the KYKLOS 4.0 Project (An Advanced Circular and Agile Manufacturing Ecosystem based on rapid reconfigurable manufacturing process and individualized consumer preferences) and by the Ministry of Science, Innovation and Universities (MCIU) via: the PriMuS project (Printing pattern based and MultiScale enhanced performance analysis of advanced Additive Manufacturing components, ref. num. PID2020-115575RB-I00). J. Baiges gratefully acknowledges the support of the Spanish Government through the Ramón y Cajal Grant RYC-2015-17367. Open Access funding provided thanks to the CRUE-CSIC agreement with Springer Nature.Peer Reviewed20222022-12-0120222022-12-05journal articlehttp://purl.org/coar/resource_type/c_6501VoRhttp://purl.org/coar/version/c_970fb48d4fbd8a85info:eu-repo/semantics/articleapplication/pdfhttps://hdl.handle.net/2117/377663https://dx.doi.org/10.1007/s00366-022-01655-0reponame:UPCommons. Portal del coneixement obert de la UPCinstname:Universitat Politècnica de Catalunya (UPC)InglésengEuropean Commission http://doi.org/10.13039/100010661 Horizon 2020 Framework Programme 872570 An Advanced Circular and Agile Manufacturing Ecosystem based on rapid reconfigurable manufacturing process and individualized consumer preferencesAgencia Estatal de Investigación http://doi.org/10.13039/501100011033 Plan Estatal de Investigación Científica y Técnica y de Innovación 2017-2020 PID2020-115575RB-I00 ANALISIS DE RENDIMIENTO MEJORADO BASADO EN PATRONES DE IMPRESION Y MULTIESCALA DE COMPONENTES DE FABRICACION ADITIVA AVANZADAopen accesshttp://purl.org/coar/access_right/c_abf2Attribution 4.0 Internationalhttp://creativecommons.org/licenses/by/4.0/info:eu-repo/semantics/openAccessoai:upcommons.upc.edu:2117/3776632026-05-27T15:37:01Z
dc.title.none.fl_str_mv A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processes
title A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processes
spellingShingle A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processes
Filho, Carlos Augusto Moreira|||0000-0003-4605-6301
Manufacturing processes--Mathematical models
Finite elements
Multi-criteria adaptive mesh refinement
Additive manufacturing
GCode-based simulation
Hierarchical octree-based meshes
Fabricació -- Models matemàtics
Àrees temàtiques de la UPC::Enginyeria dels materials
title_short A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processes
title_full A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processes
title_fullStr A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processes
title_full_unstemmed A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processes
title_sort A multi-criteria h-adaptive finite-element framework for industrial part-scale thermal analysis in additive manufacturing processes
dc.creator.none.fl_str_mv Filho, Carlos Augusto Moreira|||0000-0003-4605-6301
Caicedo Silva, Manuel Alejandro|||0000-0001-7300-799X
Cervera Ruiz, Miguel|||0000-0003-3437-6703
Chiumenti, Michele|||0000-0002-6286-7393
Baiges Aznar, Joan|||0000-0002-3940-5887
author Filho, Carlos Augusto Moreira|||0000-0003-4605-6301
author_facet Filho, Carlos Augusto Moreira|||0000-0003-4605-6301
Caicedo Silva, Manuel Alejandro|||0000-0001-7300-799X
Cervera Ruiz, Miguel|||0000-0003-3437-6703
Chiumenti, Michele|||0000-0002-6286-7393
Baiges Aznar, Joan|||0000-0002-3940-5887
author_role author
author2 Caicedo Silva, Manuel Alejandro|||0000-0001-7300-799X
Cervera Ruiz, Miguel|||0000-0003-3437-6703
Chiumenti, Michele|||0000-0002-6286-7393
Baiges Aznar, Joan|||0000-0002-3940-5887
author2_role author
author
author
author
dc.subject.none.fl_str_mv Manufacturing processes--Mathematical models
Finite elements
Multi-criteria adaptive mesh refinement
Additive manufacturing
GCode-based simulation
Hierarchical octree-based meshes
Fabricació -- Models matemàtics
Àrees temàtiques de la UPC::Enginyeria dels materials
topic Manufacturing processes--Mathematical models
Finite elements
Multi-criteria adaptive mesh refinement
Additive manufacturing
GCode-based simulation
Hierarchical octree-based meshes
Fabricació -- Models matemàtics
Àrees temàtiques de la UPC::Enginyeria dels materials
description This work presents an h-adaptive finite-element (FE) strategy to address the numerical simulation of additive manufacturing (AM) of large-scale parts. The wire-arc additive manufacturing is chosen as the demonstrative technology for its manufacturing capabilities suitable for industrial purposes. The scanning path and processing parameters of the simulation are provided via a RS-274 (GCode) file, being the same as the one delivered to the AM machine. The approach is suitable for industrial applications and can be applied to other AM processes. To identify the location in the FE mesh of the heat affected zone (HAZ), a collision detection algorithm based on the separating axis theorem is used. The mesh is continuously adapted to guarantee the necessary mesh resolution to capture the phenomena inside and outside the HAZ. To do so, a multi-criteria adaptive mesh refinement and coarsening (AMR) strategy is used. The AMR includes a geometrical criterion to guarantee the FE size within the HAZ, and a Zienkiewicz–Zhu-based a-posteriori error estimator to guarantee the solution accuracy elsewhere. Thus, the number of active FEs is controlled and mesh manipulation by the end-user is avoided. Numerical simulations comparing the h-adaptive strategy with the (reference) fixed fine meshes are performed to prove the computational cost efficiency and the solution accuracy.
publishDate 2022
dc.date.none.fl_str_mv 2022
2022-12-01
2022
2022-12-05
dc.type.none.fl_str_mv journal article
http://purl.org/coar/resource_type/c_6501
VoR
http://purl.org/coar/version/c_970fb48d4fbd8a85
dc.type.openaire.fl_str_mv info:eu-repo/semantics/article
format article
dc.identifier.none.fl_str_mv https://hdl.handle.net/2117/377663
https://dx.doi.org/10.1007/s00366-022-01655-0
url https://hdl.handle.net/2117/377663
https://dx.doi.org/10.1007/s00366-022-01655-0
dc.language.none.fl_str_mv Inglés
eng
language_invalid_str_mv Inglés
language eng
dc.relation.none.fl_str_mv European Commission http://doi.org/10.13039/100010661 Horizon 2020 Framework Programme 872570 An Advanced Circular and Agile Manufacturing Ecosystem based on rapid reconfigurable manufacturing process and individualized consumer preferences
Agencia Estatal de Investigación http://doi.org/10.13039/501100011033 Plan Estatal de Investigación Científica y Técnica y de Innovación 2017-2020 PID2020-115575RB-I00 ANALISIS DE RENDIMIENTO MEJORADO BASADO EN PATRONES DE IMPRESION Y MULTIESCALA DE COMPONENTES DE FABRICACION ADITIVA AVANZADA
dc.rights.none.fl_str_mv open access
http://purl.org/coar/access_right/c_abf2
Attribution 4.0 International
http://creativecommons.org/licenses/by/4.0/
dc.rights.openaire.fl_str_mv info:eu-repo/semantics/openAccess
rights_invalid_str_mv open access
http://purl.org/coar/access_right/c_abf2
Attribution 4.0 International
http://creativecommons.org/licenses/by/4.0/
eu_rights_str_mv openAccess
dc.format.none.fl_str_mv application/pdf
dc.source.none.fl_str_mv reponame:UPCommons. Portal del coneixement obert de la UPC
instname:Universitat Politècnica de Catalunya (UPC)
instname_str Universitat Politècnica de Catalunya (UPC)
reponame_str UPCommons. Portal del coneixement obert de la UPC
collection UPCommons. Portal del coneixement obert de la UPC
repository.name.fl_str_mv
repository.mail.fl_str_mv
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