Numerical modelling of heat transfer and experimental validation in powder-bed fusion with the virtual domain approximation
Journal article, 2020

Among metal additive manufacturing technologies, powder-bed fusion features very thin layers and rapid solidification rates, leading to long build jobs and a highly localized process. Many efforts are being devoted to accelerate simulation times for practical industrial applications. The new approach suggested here, the virtual domain approximation, is a physics-based rationale for spatial reduction of the domain in the thermal finite-element analysis at the part scale. Computational experiments address, among others, validation against a large physical experiment of 17.5 [cm3] of deposited volume in 647 layers. For fast and automatic parameter estimation at such level of complexity, a high-performance computing framework is employed. It couples FEMPAR-AM, a specialized parallel finite-element software, with Dakota, for the parametric exploration. Compared to previous state-of-the-art, this formulation provides higher accuracy at the same computational cost. This sets the path to a fully virtualized model, considering an upwards-moving domain covering the last printed layers.

High performance computing (HPC)

Additive manufacturing (AM)

Finite elements (FE)

Selective laser melting (SLM)

Thermal analysis

Powder-bed fusion (PBF)

Author

Eric Neiva

Centre Internacional de Mètodes Numèrics en Enginyeria(CIMNE)

Polytechnic University of Catalonia

Michele Chiumenti

Polytechnic University of Catalonia

Centre Internacional de Mètodes Numèrics en Enginyeria(CIMNE)

Miguel Cervera

Centre Internacional de Mètodes Numèrics en Enginyeria(CIMNE)

Polytechnic University of Catalonia

Emilio Salsi

Centre Internacional de Mètodes Numèrics en Enginyeria(CIMNE)

Polytechnic University of Catalonia

Gabriele Piscopo

Polytechnic University of Turin

Santiago Badia

Centre Internacional de Mètodes Numèrics en Enginyeria(CIMNE)

Monash University

Alberto F. Martín

Polytechnic University of Catalonia

Centre Internacional de Mètodes Numèrics en Enginyeria(CIMNE)

Zhuoer Chen

Chalmers, Industrial and Materials Science, Materials and manufacture

Monash University

Caroline Lee

Monash University

Christopher Davies

Monash University

Finite Elements in Analysis and Design

0168-874X (ISSN)

Vol. 168 103343

Subject Categories

Computational Mathematics

Computer Science

Computer Systems

DOI

10.1016/j.finel.2019.103343

More information

Latest update

11/8/2019