Three-dimensional finite element thermomechanical modeling of additive manufacturing by selective laser melting for ceramic materials

Chen, Qiang; Guillemot, Gildas; Gandin, Charles‐André; Bellet, Michel

doi:10.1016/j.addma.2017.02.005

Cited by 72 publications

(86 citation statements)

References 34 publications

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“…More precisely, an isotropic and relatively coarse mesh is obtained for the constructed workpiece while preserving a conform mesh and avoiding numerical smoothing or irregularity of this interface due to remeshing operations. This adaptive meshing/remeshing strategy significantly reduces the number of elements compared to a standard level set based front-capturing remeshing strategy [11].…”

Section: Mesh Metric In In the Vicinity Of The Construction Frontmentioning

confidence: 99%

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Macroscopic thermal finite element modeling of additive metal manufacturing by selective laser melting process

Zhang

Guillemot

Bernacki

et al. 2018

Computer Methods in Applied Mechanics and Engineering

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A 3D finite element model is developed to study heat exchange during metal selective laser melting (SLM). The approach is conducted on the scale of the part to be formed, using a level set framework to track the interface between the constructed workpiece and non-melted powder, and interface between the gas domain and the successive powder bed layers. In order to keep sustainable the computational efficiency, the powder bed deposition and the energy input are simplified by the scale of an entire layer or fractions of each layer. Layer fractions are identified directly from a description of the global laser scan plan of the part to be built. Each fraction is heated during a time interval corresponding to the exposure time to the laser beam, and then cooled down during a time interval equal to the scan time for the considered layer fraction. The global heat transfer through the part under additive construction and through the powder material non-exposed to the laser beam is simulated. To reduce the computational cost, a refining and de-refining mesh adaptation is carried out with a conform mesh strategy. Mesh sensitivity tests and validation of energy conservation are discussed. The proposed model is able to predict the temperature distribution and evolution in the constructed workpiece and non-melted powder during the SLM process at the macroscale, for parts of complex geometry.Application is shown for a nickel based alloy (IN718), but the numerical model can be easily extended to other materials by using their data sets.

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Section: Mesh Metric In In the Vicinity Of The Construction Frontmentioning

confidence: 99%

“…Concerning the material deposit scale, the powder bed is mostly assumed as a continuum medium enduring continuous evolution in order to predict its melting/solidification, the formation of the melt pool and the resulting shapes of the deposited tracks [11]. A thermal resolution is developed to predict the temperature field evolution.…”

Section: Introductionmentioning

confidence: 99%

Macroscopic thermal finite element modeling of additive metal manufacturing by selective laser melting process

Zhang

Guillemot

Bernacki

et al. 2018

Computer Methods in Applied Mechanics and Engineering

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“…A numerical finite element model applied at the scale of few single tracks has been developed for the simulation of LBM applied to ceramics (Chen et al, 2017). Two domains have been considered, namely the gas and the material.…”

Section: Presentation Of the Finite Element Modelmentioning

confidence: 99%

“…The present work aims at comparing the simulated melt pool and track shape using the model developed by Chen et al (2017) with experimental results produced by LBM of ceramic (Moniz et al, 2018). Dedicated experiments have been carried out with a specific powder-absorber mixture under different laser power and scanning speed, leading to different melted zones and track shapes.…”

Section: Introductionmentioning

confidence: 99%

Additive manufacturing of an oxide ceramic by laser beam melting—Comparison between finite element simulation and experimental results

Moniz

Chen

Guillemot

et al. 2019

Journal of Materials Processing Technology

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et al.. Additive manufacturing of an oxide ceramic by laser beam melting-Comparison between finite element simulation and experimental results. Abstract: Recent progress in the application of Laser Beam Melting (LBM) of oxide ceramics has shown promising results. However, a deeper understanding of the process is required to master and control the track development. In this approach numerical modeling could allow higher quality, of additive manufacturing for such materials, to be achieved. The validation of an earlier developed finite element model for LBM of ceramic materials has been established through a comparison with experimental results. The model solves heat and mass transfers whilst accounting for fluid flow due to surface tension and Marangoni convection, as well as tracking the material/gas boundary. The volumetric heat source parameters used in the simulations have been calibrated with an analytical model combined with original in-situ reflectance measurements. Numerical results show good agreement with measurements of melt pool dimensions and shapes. They also provide a coherent description of the evolution of the track morphology when varying the heat source parameters. Track irregularities have also been revealed by simulations at high scanning speed and the balling effect highlighted and explained through similar simulations.

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“…This undesired situation is becoming more frequent since it is increasingly common to create meshes directly from complex CAD solid geometries [14,15] or from an X-Ray tomography [16,17,18,19]. Moreover, newly developed technologies, e.g., additive manufacturing, allow to create elaborated solids, with consequent demanding numerical simulations [20,21,22]. Besides, also the presence of materials close to the incompressibility limit or a loosely constrained body can lead to an ill-conditioned system.…”

Section: Introductionmentioning

confidence: 99%

A robust adaptive algebraic multigrid linear solver for structural mechanics

Franceschini

Magri

Mazzucco

et al. 2019

Computer Methods in Applied Mechanics and Engineering

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The numerical simulation of structural mechanics applications via finite elements usually requires the solution of large-size and ill-conditioned linear systems, especially when accurate results are sought for derived variables interpolated with lower order functions, like stress or deformation fields. Such task represents the most time-consuming kernel in commercial simulators; thus, it is of significant interest the development of robust and efficient linear solvers for such applications. In this context, direct solvers, which are based on LU factorization techniques, are often used due to their robustness and easy setup; however, they can reach only superlinear complexity, in the best case, thus, have limited applicability depending on the problem size. On the other hand, iterative solvers based on algebraic multigrid (AMG) preconditioners can reach up to linear complexity for sufficiently regular problems but do not always converge and require more knowledge from the user for an efficient setup. In this work, we present an adaptive AMG method specifically designed to improve its usability and efficiency in the solution of structural problems. We show numerical results for several practical applications with millions of unknowns and compare our method with two state-of-the-art linear solvers proving its efficiency and robustness.

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Three-dimensional finite element thermomechanical modeling of additive manufacturing by selective laser melting for ceramic materials

Cited by 72 publications

References 34 publications

Macroscopic thermal finite element modeling of additive metal manufacturing by selective laser melting process

Macroscopic thermal finite element modeling of additive metal manufacturing by selective laser melting process

Additive manufacturing of an oxide ceramic by laser beam melting—Comparison between finite element simulation and experimental results

A robust adaptive algebraic multigrid linear solver for structural mechanics

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