Abstract
Additive Manufacturing (AM) processes enable their deployment in broad applications from aerospace to art, design, and architecture. Part quality and performance are the main concerns during AM processes execution that the achievement of adequate characteristics can be guaranteed, considering a wide range of influencing factors, such as process parameters, material, environment, measurement, and operators training. Investigating the effects of not only the influential AM processes variables but also their interactions and coupled impacts are essential to process optimization which requires huge efforts to be made. Therefore, numerical simulation can be an effective tool that facilities the evaluation of the AM processes principles. Selective Laser Melting (SLM) is a widespread Powder Bed Fusion (PBF) AM process that due to its superior advantages, such as capability to print complex and highly customized components, which leads to an increasing attention paid by industries and academia. Temperature distribution and melt pool dynamics have paramount importance to be well simulated and correlated by part quality in terms of surface finish, induced residual stress and microstructure evolution during SLM. Summarizing numerical simulations of SLM in this survey is pointed out as one important research perspective as well as exploring the contribution of adopted approaches and practices. This review survey has been organized to give an overview of AM processes such as extrusion, photopolymerization, material jetting, laminated object manufacturing, and powder bed fusion. And in particular is targeted to discuss the conducted numerical simulation of SLM to illustrate a uniform picture of existing nonproprietary approaches to predict the heat transfer, melt pool behavior, microstructure and residual stresses analysis.
Highlights
Additive Manufacturing (AM) processes enable the transition from analog to digital manufacturing, using Computer Aided Design (CAD) software to encourage the 3D objects are being built layer-by-layer via direct material deposition onto the substrate
AM can be helpful in two ways, either for direct prototyping in which it is used to fabricate the part, or indirect prototyping that is used to produce the tools required to be applied in conventional processes or a production assembly line such as jigs and fixtures
AM processes are summarized in Figure 1 to identify the candidate process for concerned applications and materials to provide an overview of the available technologies in comparative ways [15]
Summary
Additive Manufacturing (AM) processes enable the transition from analog to digital manufacturing, using Computer Aided Design (CAD) software to encourage the 3D objects are being built layer-by-layer via direct material deposition onto the substrate. Experimental investigation of AM processes and their parameters contribution into the component quality and performance, would be expensive in terms of time and cost that due to the vast number of the variables and their interactions which should be taken into account [9]. To alleviate these challenges in studying AM processes, numerical simulation approaches have been widely used for their visibility and forward-looking value.
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