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A modeling and simulation approach for problems with solid-liquid-solid phase transitions and a free surface, feasible for material accumulation processes based on laser-based free form heading and welding processes for joining different metallic materials is presented. Both named processes are modeled within the framework of continuum mechanics by coupling the Stefan problem with the Navier-Stokes equations including a free capillary surface.

Modeling and computation of a process with solid‐liquid‐solid phase transitions and a free capillary surface is discussed. The main components of the model are heat conduction, a free melt surface, a moving phase boundary, and its coupling with the Navier‐Stokes equations. We present two different approaches for handling the phase transitions by applying in a FE method, namely an energy conservation based approach, and a sharp interface approach with moving mesh. By combining both methods, we benefit from the advantages of the respective approach. The methods are applied to a problem where material is accumulated by melting the tip of thin steel wires using laser heating. (© 2012 Wiley‐VCH Verlag GmbH & Co. KGaA, Weinheim)

In micro manufacturing, a precise configuration of manufacturing processes constitutes an essential factor for success. The continuing miniaturization of work pieces results in ever decreasing tolerances, whereas machines and processes become more and more specialized. As a result, a precise determination of each process result is important to guarantee the final product quality. Unfortunately, so called size effects often prevent the direct transfer of knowledge from the area of macro manufacturing. To cope with these effects, finite element simulations provide a suitable tool to simulate forming processes and their results in advance and to perform parameter studies in order to analyze the process and effect interdependencies. Unfortunately, these simulations usually require a rather long computing time, so that only simulations for a small subset of the available parameter range can be performed in a reasonable planning interval. In this context, this article presents an application of the method “Micro – Process Planning and Analysis” (μ-ProPlAn) for the configuration of laser rod end melting, which is used to create preforms for further forming processes. This method uses cause-effect networks, to combine expert knowledge with methods from artificial intelligence to estimate the result of laser melting processes quickly. For this purpose, the cause-effect networks are trained using a finite element simulation of the laser process using different process parameters and varying rod diameters. Results show a high accuracy for the prediction of the finite element simulation results. This article focusses on the validation of these cause-effect networks in comparison to the real laser rod end melting process and demonstrates how these models can be used to predict the resulting volume, eccentricity and the largest diameter of the solidified preform for different process configurations.

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