Numerical modelling of parts distortion and beam supports breakage during selective laser melting (SLM) additive manufacturing

Bresson, Y.; Tongne, Amèvi; Selva, Pierre; Arnaud, Lionel

doi:10.1007/s00170-021-08501-5

Cited by 8 publications

(4 citation statements)

References 65 publications

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“…Here, 'D' is changing from '0 at damage initiation to '1' at final failure. Additionally, u pl is the equivalent plastic displacement defined as the fracture work conjugate of the yield stress after the onset of damage [38,39], u pl = 0 at damage initiation and u pl = u pl f at final failure. The equivalent plastic displacement at failure is given by…”

Section: Simulation Settingsmentioning

confidence: 99%

Effect of Scanning Strategy on Thermal Stresses and Strains during Electron Beam Melting of Inconel 625: Experiment and Simulation

et al. 2023

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This paper develops a hybrid experimental/simulation method for the first time to assess the thermal stresses generated during electron beam melting (EBM) at high temperatures. The bending and rupture of trusses supporting Inconel 625 alloy panels at ~1050 °C are experimentally measured for various scanning strategies. The generated thermal stresses and strains are thereafter simulated using the Finite-Element Method (FEM). It is shown that the thermal stresses on the trusses may reach the material UTS without causing failure. Failure is only reached after the part experiences a certain magnitude of plastic strain (~0.33 ± 0.01 here). As the most influential factor, the plastic strain increases with the scanning length. In addition, it is shown that continuous scanning is necessary since the interrupted chessboard strategy induces cracking at the overlapping regions. Therefore, the associated thermal deformation is to be minimized using a proper layer rotation according to the part length. Although this is similar to the literature reported for selective laser melting (SLM), the effect of scanning pattern is found to differ, as no significant difference in thermal stresses/strains is observed between bidirectional and unidirectional patterns from EBM.

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Section: Simulation Settingsmentioning

confidence: 99%

Effect of Scanning Strategy on Thermal Stresses and Strains during Electron Beam Melting of Inconel 625: Experiment and Simulation

et al. 2023

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“…Bresson et al [20] evaluated the predictive capabilities of commercial FEM simulation tools in terms of a crack formation between the part and its support structure in PBF-LB/M for 316L stainless steel. Due to the limitations of these tools, they set up an alternative approach applying a ductile damage criterion with a damage indicator, which allowed for a prediction of an actual part-support failure.…”

Section: Introductionmentioning

confidence: 99%

Towards a Simulation-Assisted Prediction of Residual Stress-Induced Failure during Powder Bed Fusion of Metals Using a Laser Beam: Suitable Fracture Mechanics Models and Calibration Methods

Panzer,

Wolf,

Bachmann

et al. 2023

JMMP

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In recent years, Additive Manufacturing (AM) has emerged as a transformative technology, with the process of Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) gaining substantial attention for its precision and versatility in fabricating metal components. A major challenge in PBF-LB/M is the failure of the component or the support structure during the production process. In order to locate a possible residual stress-induced failure prior to the fabrication of the component, a suitable failure criterion has to be identified and implemented in process simulation software. In the work leading to this paper, failure criteria based on the Rice-Tracey (RT) and Johnson-Cook (JC) fracture models were identified as potential models to reach this goal. The models were calibrated for the nickel-based superalloy Inconel 718. For the calibration process, a conventional experimental, a combined experimental and simulative, and an AM-adapted approach were applied and compared. The latter was devised to account for the particular phenomena that occur during PBF-LB/M. It was found that the JC model was able to capture the calibration data points more precisely than the RT model due to its higher number of calibration parameters. Only the JC model calibrated by the experimental and AM-adapted approach showed an increased equivalent plastic failure strain at high triaxialities, predicting a higher cracking resistance. The presented results can be integrated into a simulation tool with which the potential fracture location as well as the cracking susceptibility during the manufacturing process of PBF-LB/M parts can be predicted.

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“…A significant hurdle has been identified in the interactions between thermal flow and stress fields during the laser melting process. Such interactions have been linked to the onset of thermal distortions in components, potentially diminishing the integrity and efficiency of the final product [8][9][10].…”

Section: Introductionmentioning

confidence: 99%

Deep Learning-Based Cooperative Modelling of Thermal Flow and Stress Fields in Laser Powder Bed Fusion

Huang,

Huang

2023

IJHT

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In the realm of global manufacturing, the proliferation of Laser Powder Bed Fusion (LPBF) technologies has necessitated an in-depth understanding of the dynamics between thermal flow and stress fields during its operative procedures. Interactions between these fields have been observed to induce thermal distortions in components, potentially jeopardizing the structural integrity and operational efficiency of the end products. Insights have been garnered through conventional finite element methods and empirical models, yet these methodologies encounter evident constraints when deciphering highly nonlinear, multiscale systems. This research delves into the employment of deep learning techniques for the cooperative modelling of the aforementioned fields, suggesting an innovative approach to thermal distortion predictions. The outcomes derived from this inquiry are foreseen to unveil novel optimization strategies for laser melting manufacturing methodologies, propelling the evolution of this specialized field.

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Numerical modelling of parts distortion and beam supports breakage during selective laser melting (SLM) additive manufacturing

Abstract: Numerical modelling of parts distortion and beam supports breakage during selective laser melting (SLM) additive manufacturing.

Cited by 8 publications

References 65 publications

Effect of Scanning Strategy on Thermal Stresses and Strains during Electron Beam Melting of Inconel 625: Experiment and Simulation

Effect of Scanning Strategy on Thermal Stresses and Strains during Electron Beam Melting of Inconel 625: Experiment and Simulation

Towards a Simulation-Assisted Prediction of Residual Stress-Induced Failure during Powder Bed Fusion of Metals Using a Laser Beam: Suitable Fracture Mechanics Models and Calibration Methods

Deep Learning-Based Cooperative Modelling of Thermal Flow and Stress Fields in Laser Powder Bed Fusion

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