Abstract
This paper presents a novel approach to numerical modelling of selective laser melting (SLM) processes characterized by melting and solidification of the deposited particulate material. The approach is based entirely on two homogeneous methods, such as cellular automata and Lattice Boltzmann. The model components operate in the common domain allowing for linking them into a more complex holistic numerical model with the possibility to complete full-scale calculations eliminating complicated interfaces. Several physical events, occurring in sequence or simultaneously, are currently considered including powder bed deposition, laser energy absorption and heating of the powder bed by the moving laser beam leading to powder melting, fluid flow in the melted pool, flow through partly or not melted materials and solidification. The possibilities and benefits of the proposed solution are demonstrated through a series of benchmark cases, as well as model verifications. The presented case studies deal mainly with melting and solidification of the powder bed including the free surface flow, wettability, and surface tension. An example of process simulation shows that the approach is generic and can be applied to different multi-material SLM processes, where energy transfer including solid–liquid phase transformation is essential, by integrating the developed models within the proposed framework.
Highlights
In the additive manufacturing process known as selective laser melting (SLM), a moving high-power laser beam selectively melts the deposited powder material, which is solidified after the laser beam moves further scanning the required area, layer by layer, to build a three-dimensional solid component reflecting a preliminary prepared CAD model
The multiphysics simulation is based entirely on two homogeneous methods, cellular automata (CA) and Lattice Boltzmann methods (LBM). Such combination allows for efficient modelling of multi-physical phenomena accompanying the manufacturing process, but at the same time, it eliminates the complicated interfaces between different components of the model
Operating in the common domain, the model components are linked into a complex holistic numerical model with the possibility to complete the fullscale calculations within the single integrated model
Summary
In the additive manufacturing process known as selective laser melting (SLM), a moving high-power laser beam selectively melts the deposited powder material, which is solidified after the laser beam moves further scanning the required area, layer by layer, to build a three-dimensional solid component reflecting a preliminary prepared CAD model. While the above-mentioned individual physical processes can be developed by using different numerical methods discussed above, the main difficulties appear when a holistic model of the whole SLM process is considered. Development of simulation techniques based entirely on one or two homogeneous methods will allow for both modelling very complex multi-physical phenomena accompanying the manufacturing process and elimination of the complicated interfaces. The present paper addresses development of multiphysics simulation approach to SLM modelling based entirely on two homogeneous numerical methods, such as CA and LBM, dealing mainly with energy transfer problems including solid–liquid phase transformation. The mentioned events can occur in sequence or simultaneously It is important, because the holistic numerical model is generic and can be applied to different multi-material additive manufacturing processes where energy transfer including solid–liquid phase transformation is essential. The discussed models operate in the common domain allowing for linking them into a more complex holistic numerical model with the possibility to complete full-scale calculations within the integrated model
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