Abstract
Selective laser melting (SLM) constitutes an additive manufacturing (AM) method. Many issues such as thermal strain and macro-thermal deformation, which are caused by the thermal stress of different process parameters, are not clear. In this paper, an efficient and fast manufacturing simulation method was researched based on a moving heat source model and an elastoplastic theory of welding simulation, which was studied based on the thermodynamic coupling algorithm with a software-developed application for the SLM process. Subsequently, typical case results of thin and hollow plate part formation and the corresponding performances were simulated in detail. The results demonstrated that the effective thermal stress increased as the layer height increased from the surface layer to the substrate, while the thermal strain followed an approximate change rule. In addition, the stress was released from the underlying substrate when the support was removed. Moreover, the largest single axis plane stress was changed from tension to compression from the edge to the center, finally reaching equilibrium. In particular, maximum macro thermal deformation occurred at the printed support structure to the samples, displaying similar results in other locations such as the corners. Finally, the effectiveness of the simulation could be verified from the realistic printed part, which could provide proof for the quality prediction of the part that is actually forming.
Highlights
Due to the complex processing technology of thin and hollow plate parts, negative production and material loss occur through traditional machining
In practice, the metal powder is spread layer by layer followed by laser melting in Selective laser melting (SLM), which can produce a molten pool with a low-sized area and high temperature
Hand, the thermal deformation data were obtained through selection of a better set parameters the the corner and the maximum deformation amountobtained was at the the support of the parts
Summary
Due to the complex processing technology of thin and hollow plate parts, negative production and material loss occur through traditional machining. Luo et al (2018) [28] used the ANSYS APDL language to simulate the model (1 × 0.26 × 0.025 mm) molten pool and residual stress under different laser power values (8–14 W) as well as scanning speeds (100–400 mm/s) It was verified through experimental thermal stress results that the stress was mainly concentrated at the middle of the first scanning track, the terminal of each scanning track, and the edges of the forming surface. For this traditional finite element simulation, it was required to establish a finite element life–death model, a heat source movement algorithm based on ANSYS, ABAQUS, or MATLAB, along with a high amount of cell grid data processing for the calculation efficiency to exceed the technological requirements. The validity of the algorithm was proven by the experimental sample results
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