This paper describes the formulation adopted for the numerical simulation of the shaped metal deposition process (SMD) and the experimental work carried out at ITP Industry to calibrate and validate the proposed model. The SMD process is a novel manufacturing technology, similar to the multi-pass welding used for building features such as lugs and flanges on fabricated components (see Fig. 1a and b). A fully coupled thermo-mechanical solution is adopted including phase-change phenomena defined in terms of both latent heat release and shrinkage effects. Temperature evolution as well as residual stresses and distortions, due to the successive welding layers deposited, are accurately simulated coupling the heat transfer and the mechanical analysis. The material behavior is characterized by a thermo-elasto-viscoplastic constitutive model coupled with a metallurgical model. Nickel super-alloy 718 is the target material of this work. Both heat convection and heat radiation models are introduced to dissipate heat through the boundaries of the component. An in-house coupled FE software is used to deal with the numerical simulation and an ad-hoc activation methodology is formulated to simulate the deposition of the different layers of filler material. Difficulties and simplifying hypotheses are discussed. Thermo-mechanical results are presented in terms of both temperature evolution and distortions, and compared with the experimental data obtained at the SMD laboratory of ITP.
Abstract
This paper describes the formulation adopted for the numerical simulation of the shaped metal deposition process (SMD) and the experimental work carried out at ITP Industry to calibrate [...]
In this work the numerical simulation of Additive Manufacturing (AM) processes is addressed. The numerical results are compared with the experimental campaign carried out at SKLSP laboratories, where a Laser Solid Forming (LSF) machine, also referred to as Laser Engineered Net Shaping (LENS), is used to fabricate metal parts directly from CAD models. Ti-6Al-4V metal powder is injected into the molten pool created by a focused, high-energy laser beam and a layer of added material is sinterized according to the laser scanning pattern speciÖed by the user. The objectives of this paper are twofold: Örstly, this work is intended to calibrate the software for the numerical simulation of the AM process, to achieve high accuracy. Secondly, the sensitivity of the numerical model to the process parameters and modelling data is analysed. The numerical model adopts an apropos FE activation technology, which reproduces the same scanning pattern set for the numerical control system of the AM machine. This consists of a complex sequence of polylines, used to deÖne the contour of the component, and hatches patterns to Öll the inner section. The full sequence is given through the Common Layer Interface (CLI) format, a standard format for di§erent manufacturing processes such as Rapid Prototyping (RP), Shape Metal Deposition (SMD) or machining processes, among others. The result is a layer-by-layer metal deposition which can be used to build-up complex structures for components such as turbine blades, aircraft sti§eners, cooling systems, or medical implants, among others.
Abstract
In this work the numerical simulation of Additive Manufacturing (AM) processes is addressed. The numerical results are compared with the experimental campaign carried out at SKLSP laboratories, where a Laser Solid Forming (LSF) machine, also referred to as Laser Engineered Net [...]
Residual stresses and distortions are two technical obstacles for popularizing the additive manufacturing (AM) technology. The evolution of the stresses in AM components during the thermal cycles of the metal depositing process is not yet clear, and more accurate in situ measurements are necessary to calibrate and validate the numerical tools developed for its simulation. In this work a fully coupled thermo-mechanical analysis to simulate the laser solid forming (LSF) process is carried out. At the same time, an exhaustive experimental campaign is launched to measure the temperature evolution at different locations, as well as the distortions and both the stress and strain fields. The thermal and mechanical responses of single-wall coupons under different process parameters are recorded and compared with the numerical models. Good agreement between the numerical results and the experimental measurements is obtained. Sensitivity analysis demonstrates that the AM process is significantly affected by the laser power and the feeding rate, while poorly influenced by the scanning speed.
Abstract
Residual stresses and distortions are two technical obstacles for popularizing the additive manufacturing (AM) technology. The evolution of the stresses in AM components during the thermal [...]
The paper presents an up‐to‐date finite element numerical model for fully coupled thermo‐mechanical problems, focussing in the simulation of solidification processes of industrial metal parts. The proposed constitutive model is defined by a thermo‐visco‐elasto‐(visco)plastic free energy function which includes a contribution for thermal multiphase changes. Mechanical and thermal properties are assumed to be temperature‐dependent, and viscous‐like strains are introduced to account for the variation of the elastic moduli during the cooling process. The continuous transition between the initial fluid‐like and the final solid‐like behaviour of the part is modelled by considering separate viscous and elasto‐plastic responses as a function of the solid fraction. Thermo‐mechanical contact conditions between the mould and the part are specifically considered, assuming that the heat flux is a function of the normal pressure and the thermal and mechanical gaps. A fractional step method arising from an operator split of the governing equations is used to solve the non‐linear coupled system of equations, leading to a staggered product formula solution algorithm suitable for large‐scale computations. Representative simulations of industrial solidification processes are shown, and comparison of computed results using the proposed model with available experimental data is given.
Abstract
The paper presents an up‐to‐date finite element numerical model for fully coupled thermo‐mechanical problems, focussing in the simulation of solidification processes of industrial [...]