Conforming mesh modeling of multi-physics effect on residual stress in multi-layer powder bed fusion process

Abstract

The current research aims to predict the residual stress accumulation and evolution in the powder bed fusion processed multi-layer thin wall structures through a conforming mesh modeling approach. It involves the discrete element method (DEM) interfaced with the volume of fluid (VOF) method using computational fluid dynamics (CFD) coupled with the finite element method (FEM). The conforming mesh approach developed in the research predicts multi-physics, its induced porosity, and the cumulative effect on the residual stress in the powder bed fusion processed Ti-6Al-4V thin wall structures. The results of the residual stress in the multi-layered component from this method were further quantitatively compared with the non-conforming finite element method. The results show the conforming mesh approach was not only effective in capturing the layer geometry, and defects induced during the printing, but also predicted the residual stress in the region of the defect more accurately than the non-conforming mesh methods.