Model Development in OpenFOAM for Laser Metal Deposition-based Additive Manufacturing Process

Chouhan, Arvind; Aggarwal, Akash; Kumar, Arvind

doi:10.1007/s12666-018-1440-7

Cited by 7 publications

(4 citation statements)

References 7 publications

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“…1970s and 1980s, the theoretical foundations for the numerical solution of multid sional problems of hydrodynamics were laid [13,14] and the first samples of applie ware were created-SIMPLE, SIMPLER, and others [13,15,16]. At the same time, the methods of interpolation of media interface free surface boundary were proposed [ The development of computer technology in the following decades led to a sharp in in interest according to the problems of computational fluid dynamics and heat tra which caused both the creation of commercial packages and the emergence of man cialized programs [19,20]. Generally, they presented in the form of open-source sof for universal programming environments such as Visual C, C++, C#, Delphi, VB.NE The use of the described world experience and the results of our own researc made it possible to create software for studying and predicting the additive manuf ing process.…”

Section: Description Of the Model And Methods Usedmentioning

confidence: 99%

“…At the same time, the basic methods of interpolation of media interface free surface boundary were proposed [17,18]. The development of computer technology in the following decades led to a sharp increase in interest according to the problems of computational fluid dynamics and heat transfer, which caused both the creation of commercial packages and the emergence of many specialized programs [19,20]. Generally, they presented in the form of open-source software for universal programming environments such as Visual C, C++, C#, Delphi, VB.NET, etc.…”

Section: Introductionmentioning

confidence: 99%

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Mathematical Model for Metal Transfer Study in Additive Manufacturing with Electron Beam Oscillation

et al. 2021

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A computer model has been developed to investigate the processes of heat and mass transfer under the influence of concentrated energy sources on materials with specified thermophysical characteristics, including temperature-dependent ones. The model is based on the application of the volume of fluid (VOF) method and finite-difference approximation of the Navier–Stokes differential equations formulated for a viscous incompressible medium. The “predictor-corrector” method has been used for the coordinated determination of the pressure field which corresponds to the continuity condition and the velocity field. The modeling technique of the free liquid surface and boundary conditions has been described. The method of calculating surface tension forces and vapor recoil pressure has been presented. The algorithm structure is given, the individual modules of which are currently implemented in the Microsoft Visual Studio environment. The model can be applied for studying the metal transfer during the deposition processes, including the processes with electron beam spatial oscillation. The model was validated by comparing the results of computational experiments and images obtained by a high-speed camera.

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Section: Description Of the Model And Methods Usedmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Mathematical Model for Metal Transfer Study in Additive Manufacturing with Electron Beam Oscillation

et al. 2021

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“…Now it is necessary to describe the method for modeling the molten pool free surface movement. The forces acting on the free surface are given in equation ( 1) as their volumetric equivalents, such approach is widely used in practice [13][14][15]. Most often, to refer the considered control volume to an element of the free surface, the condition of a nonzero gradient of the L function is taken (∇L ≠ 0).…”

Section: Description Of the Model: Heat And Mass Transfermentioning

confidence: 99%

Modeling of heat and mass transfer and electrons scattering in electron beam welding and additive manufacturing

Щербаков

Gaponova

Gudenko

et al. 2022

J. Phys.: Conf. Ser.

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The mathematical formulation of electron beam melting and liquid metal transfer model in wire-based additive manufacturing with temperature dependencies of thermophysical properties is described. A description of the model algorithmic implementation based on the use of numerical methods for solving the Navier-Stokes equations system and the Volume of Fluid (VOF) method for tracking the free surface of a liquid on the cubic mesh cells is given. An iterative method for calculating the pressure field that ensures the fulfillment of the incompressibility condition for a viscous fluid is described. The paper also paid attention to the description of methodology for calculating the forces acting on the free surface of the melt, including surface tension forces and metal vapor pressure forces. One of the key elements of the proposed model is method for volumetric distribution of electron losses calculating, considering their scattering during the interaction of an electron beam with a curved melt surface. Electron beam focusing influence on the distribution of energy losses and the dynamics of penetration channel formation has been studied. An algorithm for visualizing the free surface of the melt based on the use of the Gaussian function, is described.

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“…This may impair the realistic simulation of the gas flow above the melt pool. OpenFOAM has also already been used for the simulation of other processes such as laser metal deposition, which was carried out by Chouhan et al [6]. Drobniak et al [7] did not use a standard OpenFOAM solver, but developed an own solver based on a not explicitly mentioned OpenFOAM solver in order to simulate the deep penetration laser welding process.…”

Section: Introductionmentioning

confidence: 99%

Implementation of the Marangoni effect in an open-source software environment and the influence of surface tension modeling in the mushy region in laser powder bed fusion (LPBF)

Wirth¹,

Tonn²,

Schöberl³

et al. 2022

Modelling Simul. Mater. Sci. Eng.

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Tangential surface tension forces on a gas–liquid interface due to surface tension gradients have been implemented in the computational fluid dynamics (CFD) solver icoReactingMultiphaseInterFoam provided by the open-source software environment of OpenFOAM OpenCFD Ltd (ESI Group) OpenFOAM (online) https://www.openfoam.com/ (accessed 21 May 2021), so that the Marangoni effect can be taken into account, which is a main driver of heat transfer in additive manufacturing processes that comprise a melt pool. The solver surpasses the capabilities of similar open-source projects by considering a wide range of physical effects, e.g. multiple phases, melting, solidification, evaporation, and laser beam heat sources with an arbitrary intensity distribution and thus makes it an appealing framework, especially for the simulation of the laser powder bed fusion (LPBF) process. Herein, all relevant details and derivation considering the Marangoni effect are provided and validated by means of a benchmark problem by comparing the obtained results with the available analytical solution, with the results obtained from a commercial CFD tool and with the results of other authors. The modified solver is additionally validated by comparing the results from LPBF simulations with experimental data. Furthermore, the influence of the surface tension modeling on the mushy region is investigated. The optimized implementation shows improvements of the simulation results in both the dimensions and shape of the melt pool and the resulting surface with regard to the experimental data.

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Model Development in OpenFOAM for Laser Metal Deposition-based Additive Manufacturing Process

Cited by 7 publications

References 7 publications

Mathematical Model for Metal Transfer Study in Additive Manufacturing with Electron Beam Oscillation

Mathematical Model for Metal Transfer Study in Additive Manufacturing with Electron Beam Oscillation

Modeling of heat and mass transfer and electrons scattering in electron beam welding and additive manufacturing

Implementation of the Marangoni effect in an open-source software environment and the influence of surface tension modeling in the mushy region in laser powder bed fusion (LPBF)

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