Abstract
A new platform for three-dimensional simulation of Additive Layer Manufacturing (ALM) processes is presented in the paper. The platform is based on homogeneous methods—the Lattice Boltzmann Method (LBM) with elements of Cellular Automata (CA). The platform represents a new computer-based engineering technique primarily focused on Selective Laser Melting (SLM) technology. Innovative computational strategies and numerical algorithms for simulation and analysis of entire powder bed-based technology with changes in state of matter (melting-solidification) are presented in the paper. The models deal mainly with heat transfer, melting and solidification, and free-surface flow. Linking LBM and CA into a complex holistic model allows for complete full-scale simulations avoiding complicated interfaces. The approach is generic and can be applied to different multi-material powder bed-based SLM processes. A methodology for the adaptation of the model to the real material (Ti-6Al-4V alloy) and processing parameters is presented. The paper presents the first quantitative results obtained on the platform and shows the ability of the model to simulate and analyze a very complex technology, entirely without a complicated interface between the sub-models. It solves the large-scale problem connected with computer-aided design and analysis of new multi-passes and multi-materials processes.
Highlights
Additive Manufacturing (AM) is a rapidly developing area of new technologies.A review can be found, for example, in [1]
The initial preparations contain calculations connected with modeled parameters: the number of iterations, the laser beam velocity, materials’ properties, and so on; they are described in the section ‘From qualitative to quantitative simulation’
The models of the Lattice Boltzmann Method (LBM) calculation module serve for simulation of such transitions presented on the state diagram (Figure 3), and in such a way they allow for modeling the whole cycle of the Selective Laser Melting (SLM) process
Summary
Additive Manufacturing (AM) is a rapidly developing area of new technologies. A review can be found, for example, in [1]. Macroscopic thermal modeling of the Selective Laser Melting process on the scale of the constructed workpiece using the 3D finite element method is presented by Zhang et al. They applied the model to a process with a relatively large laser spot, intermediate laser power, and low velocity This allows homogenization of the powder properties, but it cannot be extended to other cases. Lee and Zhang [9] modeled heat transfer, fluid flow, and solidification in processes such as SLM–laser powder bed fusion that closely resembles the weld metal microstructure but at a much finer scale. A transient three-dimensional beam-matter interaction model was developed to simulate the process of laser beam melting of metals in the powder bed by Gürtler et al [10]. A 2D model was developed to simulate grain structure evolution during powder-bed-based, layer-by-layer Additive Manufacturing. The new platform, principles, features, models, and results are presented
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