Numerical simulation of Laser Fusion Additive Manufacturing processes using the SPH method

In this work, the Smooth Particle Hydrodynamics (SPH) method, a Lagrangian mesh-free numerical scheme, is adapted for the first time to resolve thermal–mechanical–material fields in a range of Laser Fusion Additive Manufacturing processes. The method is capable of simulating large-deformation, free-...

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Bibliographic Details
Published in:Computer methods in applied mechanics and engineering 2018-11, Vol.341, p.163-187
Main Authors: Russell, M.A., Souto-Iglesias, A., Zohdi, T.I.
Format: Article
Language:English
Subjects:
Additive Manufacturing
Chemical reactions
Computational fluid dynamics
Computer simulation
Computer simulations
Deformation
Finite element method
Fluid flow
Heat flow
Incompressible flow
Incompressible fluids
Laser beam melting
Laser beam welding
Laser fusion
Laser powder bed fusion
Liquid phases
Mathematical models
Meshless methods
Process parameters
Selective Laser Melting
Smooth particle hydrodynamics
Solidification
SPH
Studies
Temperature
Theory
Thermodynamics
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Summary:In this work, the Smooth Particle Hydrodynamics (SPH) method, a Lagrangian mesh-free numerical scheme, is adapted for the first time to resolve thermal–mechanical–material fields in a range of Laser Fusion Additive Manufacturing processes. The method is capable of simulating large-deformation, free-surface melting, flow, and re-solidification of metallic materials with complex physics and material geometries. A novel SPH formulation for modeling isothermally-incompressible fluids, which allows for the accurate simulation of thermally-driven, liquid-phase metal expansion/contraction, is presented and verified. Fundamental validation of the methodology is performed via comparison with spot laser welding experiments. The methodology is then used to investigate the specific Additive Manufacturing process of the Selective Laser Melting of Metallic, micro-scale particle beds. The physics of a track deposition process is explored through numerical experiments, and the influence of processing parameters on the quality of the finished melt-track is investigated. The unique abilities of using a Lagrangian mesh-free method, as opposed to mesh-based numerical schemes, to model this process are highlighted. The SPH method is found to be a viable and promising numerical tool for simulating laser fusion driven Additive Manufacturing processes.
ISSN:0045-7825
1879-2138
DOI:10.1016/j.cma.2018.06.033