Abstract
Numerical modelling and simulation can be useful tools in qualification of additive manufactured parts for use in demanding structural applications. The use of these tools in predicting the mechanical properties and field performance of additive manufactured parts can be of great advantage. Modelling and simulation of non-linear material behaviour requires development and implementation of constitutive models in finite element analysis software. This paper documents the implementation and verification process of a microstructure-variable based model for DMLS Ti6Al4V (ELI) in two separate ABAQUS/Explicit subroutines, VUMAT and VUHARD, available for defining the yield surface and plastic deformation of materials. The verification process of the implemented subroutines was conducted for single and multiple element tests with varying prescribed loading conditions. The simulation results obtained were then compared with the analytical solutions at the same conditions of strain rates and temperatures. This comparison showed that both developed subroutines were accurate in predicting the flow stress of various forms of DMLS Ti6Al4V (ELI) under different conditions of strain rates and temperatures.
Highlights
Additive manufacturing (AM) technologies make it possible to design and fabricate lightweight metallic structural parts in real time
The microstructure- and dislocation-based constitutive model implemented as VUHARD and VUMAT subroutines was verified by determining the closeness of the results of simulation using ABAQUS to the analytical solutions based on Equation (1)
The equivalent plastic strain and von Mises stress generated from the two subroutines for the single element numerical model coincide for a large part of the simulation time
Summary
Additive manufacturing (AM) technologies make it possible to design and fabricate lightweight metallic structural parts in real time. This is plausible, as components from 3D CAD models can be printed or produced directly using an electron beam source for electron beam melting (EBM) [1] or a laser source for selective laser melting (SLM)/direct metal laser sintering (DMLS) [1] on a powder bed table. Complex components with hollows and undercuts, such as turbine blades with internal cooling channels, are being produced by AM [2]. Other complex components produced by this technology are patient-specific bio-implants such as dental prostheses and orthopaedic implants [3]. The AM-produced components possess increased applications in the biomedical and aerospace industries
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