Short review on modeling approaches for metal additive manufacturing process

Abstract

Additive manufacturing (AM) has been gaining considerable attention from both industrial and research communities the recent years. Main challenges in AM modeling arise from the accurate estimation of nodal temperature history, distribution of residual stresses and distortion of parts fabricated by AM and also from high computational efforts. Innovative solutions were proposed and implemented to address these issues in the AM processes of metal alloys and also modeling methods were developed to further improve efficiency and accuracy of the process. The current paper provides a short review on the thermomechanical modeling approaches and techniques developed for residual stress and distortion assessment of direct metal deposition (DMD) of AM parts. The beneficial outcomes and shortages of the recent studies in AM modeling were presented and discussed.

A Review- Modelling Approach and Numerical Analysis of Additive Manufacturing

“…The mechanical or structure analysis stage, however, dominates the analysis time in decoupled modelling. Since the thermal gradient near the thermal source is extremely strong, the mesh size must be adequate to capture the high graded residual stress and distortion of the diffusion layer and many layers beneath it: in the heat affected zone (HAZ) [23]. As a result, when a fine mesh is used in the model, the computational time increases.…”

“…In two steps, the adaptable meshing technique is used: fine mapping and coarsening steps which utilizes the concept of coherent strain. The model can be separated into three separate scales (micro, meso, and macro), the mechanical layer equivalent can be achieved [23]. With a true thermal heat model structure and thermal boundary conditions, a pure thermal analysis is done on a very small structure that is connected to a substrate that replicates the lower layers from the real scale.…”

A High-Performance Modeling Approach Of Artificial Neural Network And Finite Element Analysis For Residual Stress Prediction Of Direct Metal Deposition Process

“…UMATHT subroutine is developed for each structure to account for the element activation and also for introducing temperature-dependent material properties to the FE model. Activation of elements and layers were carried out by implementing hybrid element activation technique [6,[11][12]. DFLUX subroutine was implemented to provide flexibility in generating desired laser path in conjunction with ABAQUS.…”

Survey of Modeling and Simulation Techniques for Advanced Manufacturing Technologies Volume I – Predicting Initial Microstructures

“…If, on the other hand, the mechanical analysis is done after the entire thermal analysis is completed then the thermomechanical analysis is decoupled. Both types of analysis have its advantages and disadvantages: the coupled analysis yields more precise results, whereas the decoupled analysis yields results that are about 4x faster than the fully coupled analysis [197]. In general, the AMT community tends to favor the decoupled thermomechanical analysis since the loss of precision is minor when compared to the uncertainties that arise from other parts of the process.…”