Numerical investigations on hatching process strategies for powder-bed-based additive manufacturing using an electron beam

Markl, Matthias; Ammer, Regina; Rüde, Ulrich; Körner, Carolin

doi:10.1007/s00170-014-6594-9

Cited by 45 publications

(25 citation statements)

References 24 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…For a review focused on modeling of FDM/FFF see, for example, Turner et al 2014 andGold 2015. While fully resolved numerical simulation of the type presented here are still very rare for FDM/FFF, efforts to simulate other additive manufacturing processes are starting. For laser powder bed fusion processes, where a laser is used to selectively fuse or sinter metal particles, researchers at the Lawrence Livermore National Laboratory have developed comprehensive computational models that have been used to examine the denudation and other aspects of metal powders, see Khairallah and Anderson 2014;King, Anderson, Ferencz, Hodge, Kamath, Khairallah and Rubenchik 2015;Markl et al 2015;Matthews et al 2016 andKhairallah et al 2016. Several years ago there was also considerable interest in examining how objects could be built either by depositing drops one by one (Gao and Sonin 1994) or by spraying molten metal on a substrate (Liu et al 1993;Chung and Rangel 2001;Mostaghimi et al 2002;Che et al 2004).…”

Section: Introductionmentioning

confidence: 99%

Fully resolved numerical simulations of fused deposition modeling. Part II – solidification, residual stresses and modeling of the nozzle

Xia

Tryggvason

2018

RPJ

View full text Add to dashboard Cite

Purpose -This paper continues the development of a comprehensive methodology for fully resolved numerical simulations of fusion deposition modeling. Design/methodology/approach -A front-tracking/finite volume method introduced in Part I to simulate the heat transfer and fluid dynamics of the deposition of a polymer filament on a fixed bed is extended by adding an improved model for the injection nozzle, including the shrinkage of the polymer as it cools down, and accounting for stresses in the solid. Findings -The accuracy and convergence properties of the new method are tested by grid refinement and the method is shown to produce convergent solutions for the shape of the filament, the temperature distribution, the shrinkage and the solid stresses.Research limitations/implications -The method presented in the paper focuses on modeling the fluid flow, the cooling and solidification, as well as volume changes and residual stresses, using a relatively simple viscoelastic constitutive model. More complex material models, depending, for example, on the evolution of the configuration tensor, are not included. Practical implications -The ability to carry out fully resolved numerical simulations of the fusion deposition process is expected to be critical for the validation of mathematical models for the material behavior, to help explore new deposition strategies, and to provide the "ground truth" for the development of reduced order models. Originality/value -The paper completes the development of the first numerical method for fully resolved simulation of fusion filament modeling. arXiv:1711.07094v2 [physics.flu-dyn]

show abstract

Section: Introductionmentioning

confidence: 99%

Fully resolved numerical simulations of fused deposition modeling. Part II – solidification, residual stresses and modeling of the nozzle

Xia

Tryggvason

2018

RPJ

View full text Add to dashboard Cite

show abstract

“…Figure 14a). Furthermore, together with an advection-diffusion LBM implementation, it has been used to simulate an electron beam that melts a powder bed in additive manufacturing [138,139], as shown in Figure 14b.…”

Section: Free Surface Lattice Boltzmann Methodsmentioning

confidence: 99%

waLBerla: A block-structured high-performance framework for multiphysics simulations

Bauer

Eibl

Godenschwager

et al. 2021

Computers & Mathematics with Applications

Self Cite

View full text Add to dashboard Cite

Programming current supercomputers efficiently is a challenging task. Multiple levels of parallelism on the core, on the compute node, and between nodes need to be exploited to make full use of the system. Heterogeneous hardware architectures with accelerators further complicate the development process. waLBerla addresses these challenges by providing the user with highly efficient building blocks for developing simulations on block-structured grids. The block-structured domain partitioning is flexible enough to handle complex geometries, while the structured grid within each block allows for highly efficient implementations of stencil-based algorithms. We present several example applications realized with waLBerla, ranging from lattice Boltzmann methods to rigid particle simulations. Most importantly, these methods can be coupled together, enabling multiphysics simulations. The framework uses meta-programming techniques to generate highly efficient code for CPUs and GPUs from a symbolic method formulation. To ensure software quality and performance portability, a continuous integration toolchain automatically runs an extensive test suite encompassing multiple compilers, hardware architectures, and software configurations.

show abstract

“…Due to the high computational demand, no additional modules are implemented and a special high performance platform designed for supercomputers [25] is used. Further model details [19] and applications [26] on PBF are published.…”

Section: Core Modulesmentioning

confidence: 99%

S𝔸𝕄PLE: A Software Suite to Predict Consolidation and Microstructure for Powder Bed Fusion Additive Manufacturing

et al. 2019

Self Cite

View full text Add to dashboard Cite

Powder bed fusion comprises all layer‐by‐layer additive manufacturing technologies of parts built from a powder bed. To exploit the advantages of near‐net shape manufacturing of complex geometries, in contrast to conventional manufacturing techniques, it is essential to understand the underlying physical phenomena occurring during processing for a broad range of different process scenarios. Experimental approaches are costly in time and material and provide only limited access inside the process. However, to understand the process behavior and predict final properties of parts, numerical approaches are powerful tools. This work presents the software suite S𝔸𝕄PLE (Simulation of Additive Manufacturing on the Powder scale using a Laser or Electron beam) which simulates the consolidation and microstructure evolution during beam‐based powder bed fusion processes. It is based on a mesoscopic approach, in which statistical powder beds, melt pool dynamics, evaporation effects, and microstructure evolution are considered and can simulate the build‐up of more than 100 layers. The underlying models and algorithms of the software including a newly applied thermal model are described. Finally, the unique potential of the software is demonstrated by reviewing the influence of various powder bed properties, the effects of evaporation, and the grain structure evolution in the process.

show abstract

Numerical investigations on hatching process strategies for powder-bed-based additive manufacturing using an electron beam

Cited by 45 publications

References 24 publications

Fully resolved numerical simulations of fused deposition modeling. Part II – solidification, residual stresses and modeling of the nozzle

Fully resolved numerical simulations of fused deposition modeling. Part II – solidification, residual stresses and modeling of the nozzle

waLBerla: A block-structured high-performance framework for multiphysics simulations

S𝔸𝕄PLE: A Software Suite to Predict Consolidation and Microstructure for Powder Bed Fusion Additive Manufacturing

Contact Info

Product

Resources

About