Investigation of thermal responses during metallic additive manufacturing using a “Tri-Prism” finite element method

Liu, Pengwei; Cui, Xiangyang; Deng, Jiashan; She, Li; Li, Zichao; Chen, Lei

doi:10.1016/j.ijthermalsci.2018.10.022

Cited by 22 publications

(4 citation statements)

References 52 publications

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“…The results from these finite element experiments are promising, demonstrating that a high level of precision can be achieved in real-time simulations using the proposed methodology. Some newly developed numerical methods such as the node-based smoothed FEM [24,38], smoothed point interpolation method [39], gradient weighted FEM [23], and "Tri-Prism" FEM [21] are focused more on the numerical accuracy, convergence and stability rather than the real-time computational performance, the proposed FED-FEM algorithm may be incorporated into these methods for improved computational performance.…”

Section: Discussionmentioning

confidence: 99%

“…Many engineering applications, such as the virtual-reality or augmented-reality-based applications, require realistic and real-time solution of transient heat transfer problems [19]; however, most of the developed numerical methods [20][21][22][23][24] are focused on the former (numerical accuracy, convergence, and stability), rather than the computation time to satisfy the conflicting requirements. Heat transfer problems are complex in terms of material characteristics which may be time/temperature-dependent and heat transfer behaviours such as heat convection and radiation, leading to nonlinear characteristics of transient heat transfer problems [22].…”

Section: Introductionmentioning

confidence: 99%

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Fast explicit dynamics finite element algorithm for transient heat transfer

Zhang

Chauhan

2019

International Journal of Thermal Sciences

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This paper presents a novel methodology for fast simulation and analysis of transient heat transfer problems. The proposed methodology is suitable for real-time applications owing to (i) establishing the solution method from the viewpoint of computationally efficient explicit dynamics, (ii) proposing an element-level thermal load computation to eliminate the need for assembling global thermal stiffness matrix, leading to (iii) an explicit formulation of nodal temperature computation to eliminate the need for iterations anywhere in the algorithm, (iv) pre-computing the constant matrices and simulation parameters to facilitate online calculation, and (v) utilising computationally efficient finite elements to efficiently obtain thermal responses in the spatial domain, all of which lead to a significant reduction in computation time for fast run-time simulation. The proposed fast explicit dynamics finite element algorithm (FED-FEM) employs nonlinear thermal material properties, such as temperature-dependent thermal conductivity and specific heat capacity, and nonlinear thermal boundary conditions, such as heat convection and radiation, to account for the nonlinear characteristics of transient heat transfer problems. Simulations and comparison analyses demonstrate that not only can the proposed methodology handle isotropic, orthotropic, anisotropic and temperature-dependent thermal properties but also satisfy the standard patch tests and achieve good agreement with those of the commercial finite element analysis packages for numerical accuracy, for three-dimensional (3-D) heat conduction, convection, radiation, and thermal gradient concentration problems. Furthermore, the proposed FED-FEM algorithm is computationally efficient and only consumes a small computation time, capable of achieving real-time computational performance, leading to a novel methodology suitable for real-time simulation and analysis of transient heat transfer problems.

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Fast explicit dynamics finite element algorithm for transient heat transfer

Zhang

Chauhan

2019

International Journal of Thermal Sciences

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“…By consideration of the melt pool geometry, double ellipsoid heat source model was originally proposed by Goldak et al [49] and then widely used in welding simulations [50][51][52][53]. The double ellipsoid heat source model in laser additive manufacturing can be written as [54][55][56],…”

Section: Double Ellipsoid Heat Source Modelmentioning

confidence: 99%

A Review on Modelling and Simulation of Laser Additive Manufacturing: Heat Transfer, Microstructure Evolutions and Mechanical Properties

Zhang

Wang

2022

Coatings

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Modelling and simulation are very important for revealing the relationship between process parameters and internal variables like grain morphology in solidification, precipitate evolution, and solid-state phase transformation in laser additive manufacturing. The impact of the microstructural changes on mechanical behaviors is also a hot topic in laser additive manufacturing. Here we reviewed key developments in thermal modelling, microstructural simulations, and the predictions of mechanical properties in laser additive manufacturing. A volumetric heat source model, including the Gaussian and double ellipsoid heat sources, is introduced. The main methods used in the simulation of microstructures, including Monte Carlo method, cellular automaton, and phase field method, are mainly described. The impacts of the microstructures on mechanical properties are revealed by the physics-based models including a precipitate evolution based model and dislocation evolution based model and by the crystal plasticity model. The key issues in the modelling and simulation of laser additive manufacturing are addressed.

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“…However, high-fidelity modeling of the additive manufacturing process has proven difficult due to the influence of multi-scale and multi-physics phenomena such as nucleation and solidification, powder packing and multi-pass effects, fluid flow and Marangoni effects, martensitic transformations, as well as the contribution from defects such as key-holing, lack of fusion, vaporization, solute segregation, and hot cracking. As such, various simulation techniques have been employed to capture different mechanisms of the fabrication process, including phase field modeling (PFM) [23] , [24] , [25] , [26] , kinetic Monte Carlo (kMC) [27] , [28] , the finite element method (FEM) [21] , [29] , [30] , [31] , [32] , [33] , computational fluid dynamics (CFD) [20] , [34] , and cellular automata (CA) [35] , [36] , [37] , [38] , [39] .…”

Section: Introductionmentioning

confidence: 99%

Fast-throughput simulations of laser-based additive manufacturing in metals to study the influence of processing parameters on mechanical properties

McElfresh,

Wang,

Marian

2024

Heliyon

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Investigation of thermal responses during metallic additive manufacturing using a “Tri-Prism” finite element method

Cited by 22 publications

References 52 publications

Fast explicit dynamics finite element algorithm for transient heat transfer

Fast explicit dynamics finite element algorithm for transient heat transfer

A Review on Modelling and Simulation of Laser Additive Manufacturing: Heat Transfer, Microstructure Evolutions and Mechanical Properties

Fast-throughput simulations of laser-based additive manufacturing in metals to study the influence of processing parameters on mechanical properties

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