The Finite Element Method for the Thermo-Mechanical Modeling of Additive Manufacturing Processes

Gouge, Michael; Michaleris, P.; Denlinger, Erik R.; Irwin, J. David

doi:10.1016/b978-0-12-811820-7.00003-3

Cited by 43 publications

(44 citation statements)

References 10 publications

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“…The main advantage of this activation procedure is that the smaller and less ill‐conditioned stiffness matrix can be generated and the computational effort can be minimized. A number of research works have been conducted based on these activation methods . Among them, the hybrid activation method which takes advantage of both quiet and inactive activation methods in terms of reducing the computational effort.…”

Section: Basics In the Modeling Of Ammentioning

confidence: 99%

“…The AM method firstly emerged as the primary tool in rapid prototyping in the 1980s with the aim of helping designers in the realistic development of complex products . The AM is based on the layer‐by‐layer deposition of a near net shape component using a laser or electron beam as the thermal source . The thermal source melts the material in form of powder or wire that is fed into the melt pool and the deposited material quickly solidifies on the substrate.…”

Section: Introductionmentioning

confidence: 99%

“…Therefore, research studies have recently focused on developing numerical‐based models that could outline the thermophysical phenomena of the AM process. Finite element (FE)‐based thermomechanical models were developed to assess thermal cycles of AM parts as the result of the heat source and obtain the mechanical response of the AM parts by enforcing the temperature history into the built part . The aforementioned models commonly make some simplifying assumptions or employ certain techniques to investigate the material deposition onto the substrate and formation of residual stresses and geometrical distortions in AM parts.…”

Section: Introductionmentioning

confidence: 99%

“…[1][2][3] The AM is based on the layer-by-layer deposition of a near net shape component using a laser or electron beam as the thermal source. 4 The thermal source melts the material in form of powder or wire that is fed into the melt pool and the deposited material quickly solidifies on the substrate. These sequences are repeated to build a complete geometry of a part on the basis of using a computer-aided design (CAD) model.…”

Section: Introductionmentioning

confidence: 99%

“…Finite element (FE)-based thermomechanical models were developed to assess thermal cycles of AM parts as the result of the heat source and obtain the mechanical response of the AM parts by enforcing the temperature history into the built part. 4,7,10,[12][13][14][15][16][17][18][19][20][21][22][23] The aforementioned models commonly make some simplifying assumptions or employ certain techniques to investigate the material deposition onto the substrate and formation of residual stresses and geometrical distortions in AM parts. Based on the comprehensiveness of the model, the numerical assessment yields reliable and precise results.…”

Section: Introductionmentioning

confidence: 99%

See 4 more Smart Citations

Short review on modeling approaches for metal additive manufacturing process

Hajializadeh

Ince

2019

Mat Design & Process Comms

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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.

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Section: Basics In the Modeling Of Ammentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Short review on modeling approaches for metal additive manufacturing process

Hajializadeh

Ince

2019

Mat Design & Process Comms

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On accurate time integration for temperature evolutions in additive manufacturing

Kollmannsberger

Kopp

2021

GAMM-Mitteilungen

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We investigate two numerical challenges in thermal finite element simulations of laser powder bed fusion (LPBF) processes. First, we compare the behavior of first‐ and second‐order implicit time‐stepping schemes on a fixed domain. While both methods yield comparable accuracies in the pre‐asymptotic regime, the second‐order method eventually outperforms the first‐order method. However, the oscillations present in the pre‐asymptotic range of the second‐order method can render it less suitable for simulating LPBF processes. Then, we consider sudden domain extensions resulting from subsequently adding new layers of material with ambient temperature. We model this extension on the continuous level in an energy conservative manner. The discontinuities introduced here reduce the convergence order for both time‐stepping schemes to 0.75. First and second order accuracy could only be achieved by strongly grading the time‐steps towards the domain expansion.

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A finite addition of matter elements method for modeling and solution of an SLM thermal problem by a multiscale method

Ruyssen

Dhia

2022

Numerical Meth Engineering

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In this paper, we are interested in flexible modeling and performing solution of transient thermal Selective Laser Melting Problems. For this, we first introduce a Finite Addition of Matter Elements Method (FAMEM) to generate any wished finite sequence of thermal problems, defined in additively constructed domains. Second, we use the Multiscale Arlequin Frame-work to develop a three-level Arlequin weakstrong formulation of each problem of the finite sequence. Two Arlequin patches are used in the latter to localize the steepest thermal gradients and the nonlinear phase-change phenomena, allowing for fine local approximations and the localized nonlinearity treatment by an algorithm we develop. These patches are identified via the solution of a representative mono-domain transient thermal problem. The latter is also solved with our three-Level Arlequin method for comparison of the solutions and respective performances of both approaches.Moreover, two dimensional tests consisting in the creation of a 316 L stainless steel wall and a two AlSi10Mg layers, are carried out to further enlighten our global approach and to position it with respect to literature.

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The Finite Element Method for the Thermo-Mechanical Modeling of Additive Manufacturing Processes

Cited by 43 publications

References 10 publications

Short review on modeling approaches for metal additive manufacturing process

Short review on modeling approaches for metal additive manufacturing process

On accurate time integration for temperature evolutions in additive manufacturing

A finite addition of matter elements method for modeling and solution of an SLM thermal problem by a multiscale method

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