HPC approach to the fully transient, three dimensional laser materials processing simulation software (ftLMPs) with particular focus on laser cutting

Abstract

In this paper the authors present their work on the fully transient, three dimensional laser materials processing simulation software (ftLMPs) developed over the last four years. To date the numerical simulation of laser materials processing has successfully evaded thorough treatment, especially of the laser cutting process. This is mainly due to the complexity of the process, and the intrinsic highly dynamic behavior of the melt pool and the assist gas jet. Contrary to the usual approach of adjusting the simulation aims towards commonly available hardware, the authors utilize state-of-the-art massively parallel computers to tackle the problem in a comprehensive manner. The complete simulation includes an assist gas simulation with pressures up to and exceeding 18 bar, evaporation of the melt (kinetic theory approach), flow patterns in the melt film/pool and thermal stresses in the substrate. It also resolves the physical domain down to the micro-scale. The combination of modern powerful numerical routines and high performance computing (HPC) methods provides a powerful unified tool for the simulation of laser materials processing over which the authors have full control. The authors will outline first results and highlight the current limits of and costs involved in using contemporary HPC platforms, in particular the IBM p690 turbo, in the context of laser materials processing. Furthermore, the authors invite collaboration and discussion of further enhancements and extensions to the software following the presentation.In this paper the authors present their work on the fully transient, three dimensional laser materials processing simulation software (ftLMPs) developed over the last four years. To date the numerical simulation of laser materials processing has successfully evaded thorough treatment, especially of the laser cutting process. This is mainly due to the complexity of the process, and the intrinsic highly dynamic behavior of the melt pool and the assist gas jet. Contrary to the usual approach of adjusting the simulation aims towards commonly available hardware, the authors utilize state-of-the-art massively parallel computers to tackle the problem in a comprehensive manner. The complete simulation includes an assist gas simulation with pressures up to and exceeding 18 bar, evaporation of the melt (kinetic theory approach), flow patterns in the melt film/pool and thermal stresses in the substrate. It also resolves the physical domain down to the micro-scale. The combination of modern powerful numerical routine...