A Directed Energy Deposition Additive Manufacturing Process Simulated with ABAQUS AM Modeler

Abstract

In this work, the ABAQUS AM modeler was employed to simulate a Directed Energy Deposition (DED) additive manufacturing process. The modeler provides an automated interface to prescribe the imposed tool path and process conditions. Though it may take some effort to understand how to use this element-birth technique approach, it is definitely worth the effort if you want to simulate additive manufacturing or similar processes. Two event series were utilized to prescribe material deposition and heat input. The automated element activation sequence was used to fabricate a thin (4 × 20 × 50 mm) and a thick (12 × 20 × 50 mm) wall component on a substrate. To approximate the 3D printing layer built up process, where filler metal is laid row by row after each scan, the component was fabricated with 10 successive layers (1 element through depth for each build layer), and each layer with 25 successive element rows. Once the first layer is deposited, the energy source and the nozzle are moved upwards to deposit the next layer and the process is repeated until the complete 3D object is being fabricated. It was found that to simulate problems where material and heat are added in a time and space dependent way, the use of the *ELEMENT PROGRESSIVE ACTIVATION option is much simpler than its counterpart *MODEL CHANGE. The AM Modeler helps to properly define the required data to approximate in a simple manner the 3D printing layer built up process. A laser path script was created in python language to allow for the path of the energy source and the nozzle. A right combination of printing parameters (feedstock and heat input) in the DED process has been established.

Effect of Finite Element Mesh Size and Time-Increment on Predicting Part-Scale Temperature for Powder Bed Fusion Process

“…A lot of effort is put into studying temperature evolution during PBF processes, using commercially available finite element (FE) packages [5][6][7]. Recent studies [8][9][10] have validated the use of the Abaqus plugin which simplifies laser path manipulation. For such a case, simulation is usually conducted in two sequentially coupled steps:…”