Multi-Objective Optimization of Selective Laser Melting Processes for Minimizing Energy Consumption and Maximizing Product Tensile Strength

Zhu, Chengcheng; Chen, Xiaoming; Wu, Honglin; Zhu, Jun; Peng, Tao; Lv, Jingxiang; Wu, Yicheng

doi:10.3390/met12111782

Cited by 7 publications

(3 citation statements)

References 49 publications

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“…During that period, researchers concentrated their efforts on enhancing the thermal and exergy efficiency while minimizing energy losses in individual pieces of equipment, guided by the principles of the first and second laws of thermodynamics. It has been emphasized that effective measures to reduce energy loss and enhance efficiency involve adjustments to material structure, technological parameters, structural parameters, and so on [10][11][12]. For instance, Feng et al [13] optimized the sintering cooling machine, aiming to maximize exergy output.…”

Section: Introductionmentioning

confidence: 99%

Theoretical Energy Consumption Analysis for Sustainable Practices in Iron and Steel Industry

Na,

Sun,

Yuan

et al. 2024

Metals

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Exploring theoretical energy consumption introduces a fresh perspective for energy-saving research within the iron and steel industry, with a primary focus on the energy expended during material transformation. Building upon the theory of theoretical energy consumption, this study meticulously investigates the theoretical energy consumption associated with each stage of the iron and steel making process, including coking, sintering, pelletizing, ironmaking, steelmaking, and hot rolling. The findings reveal that, under specific conditions, the theoretical energy consumption for each process is as follows: coking (2.59 GJ), sintering (1.36 GJ), pelletizing (1.02 GJ), ironmaking (8.81 GJ), steelmaking (−0.16 GJ), and hot rolling (0.76 GJ). Additionally, this study delves into the analysis of influencing factors on theoretical energy consumption. Using the coking process as an illustrative example, it is observed that the theoretical energy consumption in coking decreases with a reduction in both moisture and volatile content in coal. Under the specified conditions, the minimum theoretical energy consumption for each process is as follows: coking (2.51 GJ), sintering (0.98 GJ), pelletizing (0.67 GJ), ironmaking (8.38 GJ), steelmaking (−0.58 GJ), and hot rolling (0.07 GJ), respectively. This comprehensive analysis serves as a valuable resource for advancing sustainable practices in the iron and steel industry.

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Section: Introductionmentioning

confidence: 99%

Theoretical Energy Consumption Analysis for Sustainable Practices in Iron and Steel Industry

Na,

Sun,

Yuan

et al. 2024

Metals

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“…Their results showed that rubber recoating blades with a larger contact surface area and mid-range recoating velocities (10-80 mm/s) yield more uniform and compact powder layers, improving the printing quality while reducing the risk of recoater damages. Finally, it was found that the recoating speed directly affects the inter-layer cooling time and, thus, the heat accumulated in the build as well as its mechanical response [30,31]. Hence, using the right recoating speed helps to reduce the risk of the recoater impacting the deformed geometry of the AM build.…”

Section: Introductionmentioning

confidence: 99%

Recoater-Induced Distortions and Build Failures in Selective Laser Melting of Thin-Walled Ti6Al4V Parts

Chiumenti

Cervera

et al. 2023

JMMP

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Additively manufactured thin-walled structures through selective laser melting (SLM) are of great interest in achieving carbon-neutral industrial manufacturing. However, residual stresses and warpages as well as recoater crashes often occur in SLM, leading to the build failure of parts, especially for large-scale and lightweight geometries. The challenge in this work consists of investigating how the recoater affects the warpage and (sometimes) causes the failure of different thin-walled Ti6Al4V parts (wall thickness of 1.0 mm). All these parts are printed on the same platform using a commercial SLM machine. After the loose powder removal and before the cutting operation, a 3D-scanner is used to obtain the actual warpage of each component. Next, an in-house coupled thermo-mechanical finite element model suitable for the numerical simulation of the SLM process is enhanced to consider the recoater effects. This numerical framework is calibrated to predict the thin-walled warpage as measured by the 3D-scanner. The combination of numerical predictions with experimental observations facilitates a comprehensive understanding of the mechanical behavior of different thin-walled components as well as the failure mechanism due to the recoater. The findings show that the use of a higher laser energy input causes larger residual stresses and warpage responsible for the recoater crashes. Finally, potential solutions to mitigate the warpage and the recoater crashes in the SLM of lightweight structures are assessed using the validated model.

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“…This approach yielded favourable trade-offs for dimensional accuracy and surface roughness. Similarly, Zhu et al [21] employed the NGSA-II algorithm to optimize tensile strength and energy consumption in the Selective Laser Melting (SLM) process. Chinchanikar et al [22] harnessed NSGA-II to minimize surface roughness and enhance tensile strength.…”

Section: Introductionmentioning

confidence: 99%

Multi-Objective Optimization of Tensile Strength and Material Consumption of FDM Parts using Multi-Objective Symbiotic Organisms Search (MOSOS)

Saad,

Zakaria,

Baharudin

et al. 2023

Preprint

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Fused Deposition Modeling (FDM) has emerged as a prominent method for rapid prototyping in Additive Manufacturing (AM) due to its ability to construct intricate geometries. Nevertheless, optimizing FDM process parameters to attain desired part characteristics remains a challenge. This study presents comprehensive findings from an experimental investigation, comparing results obtained through simulations and practical experiments, within the framework of multi-objective optimization for FDM. The core objectives of this analysis center on material consumption and tensile strength, both pivotal in FDM applications, while exploring the efficacy of Multi-Objective Symbiotic Organisms Search (MOSOS) in addressing the trade-off between these objectives. This study utilizes advanced experimental design techniques, specifically Response Surface Methodology (RSM) in conjunction with Face-Centered Central Composite Design (FCCD), to meticulously conduct experiments. These experiments are crucial in the creation of precise regression models that serve as objective functions for the MOSOS algorithm. The significant outcome of this study is the identification of a trade-off relationship between material consumption and tensile strength in FDM. The research revealed that achieving higher tensile strength in FDM requires an increase in material consumption, while reducing material usage comes at the cost of compromised tensile strength. The study also pinpointed an optimal configuration at the fourth index, consisting of specific parameter settings such as a layer thickness of 0.25 mm, printing speed of 60 mm/s, infill density of 20%, and print temperature of 213.26°C, which strikes a satisfactory balance between material efficiency and mechanical performance.

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Multi-Objective Optimization of Selective Laser Melting Processes for Minimizing Energy Consumption and Maximizing Product Tensile Strength

Cited by 7 publications

References 49 publications

Theoretical Energy Consumption Analysis for Sustainable Practices in Iron and Steel Industry

Theoretical Energy Consumption Analysis for Sustainable Practices in Iron and Steel Industry

Recoater-Induced Distortions and Build Failures in Selective Laser Melting of Thin-Walled Ti6Al4V Parts

Multi-Objective Optimization of Tensile Strength and Material Consumption of FDM Parts using Multi-Objective Symbiotic Organisms Search (MOSOS)

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