A SIMULATION STUDY ON THE EFFECT OF PARTICLE SIZE DISTRIBUTION ON THE PRINTED GEOMETRY IN SELECTIVE LASER MELTING
Artikel i vetenskaplig tidskrift, 2021

Selective laser melting (SLM) process is a powder bed fusion additive manufacturing process that finds applications in aerospace and medical industries for its ability to produce complex geometry parts. As the raw material used is in powder form, particle size distribution (PSD) is a significant characteristic that influences the build quality in turn affecting the functionality and aesthetics aspects of the product. This paper investigates the effect of PSD on the printed geometry for 316L stainless steel powder, where three coupled in-house simulation tools based on Discrete Element Method (DEM), Computational Fluid Dynamics (CFD), and Structural Mechanics are employed. DEM is used for simulating the powder bed distribution based on the different powder PSD. The CFD is used as a virtual testbed to determine thermal parameters such as heat capacity and thermal conductivity of the powder bed viewed as a continuum. The values found as a stochastic function of the powder distribution is used to analyse the effect on the melted zone and deformation using Structural Mechanics. Results showed that mean particle size and PSD had a significant effect on the packing density, melt pool layer thickness, and the final layer thickness after deformation. Specifically, a narrow particle size distribution with smaller mean particle size and standard deviation produced solidified final layer thickness closest to nominal layer thickness. The proposed simulation approach and the results will catalyze in development of geometry assurance strategies to minimize the effect of particle size distribution on the geometric quality of the printed part.

multiphysics modeling

geometric variation

selective laser melting,

particle size distribution

316L stainless steel

Författare

Vaishak Ramesh Sagar

Chalmers, Industri- och materialvetenskap, Produktutveckling

Samuel Lorin

Stiftelsen Fraunhofer-Chalmers Centrum för Industrimatematik

Johan Göhl

Stiftelsen Fraunhofer-Chalmers Centrum för Industrimatematik

Johannes Quist

Stiftelsen Fraunhofer-Chalmers Centrum för Industrimatematik

Klas Jareteg

Stiftelsen Fraunhofer-Chalmers Centrum för Industrimatematik

Christoffer Cromvik

Stiftelsen Fraunhofer-Chalmers Centrum för Industrimatematik

Andreas Mark

Stiftelsen Fraunhofer-Chalmers Centrum för Industrimatematik

Fredrik Edelvik

Stiftelsen Fraunhofer-Chalmers Centrum för Industrimatematik

Kristina Wärmefjord

Chalmers, Industri- och materialvetenskap, Produktutveckling

Rikard Söderberg

Chalmers, Industri- och materialvetenskap

Journal of Manufacturing Science and Engineering, Transactions of the ASME

1087-1357 (ISSN)

Ämneskategorier

Produktionsteknik, arbetsvetenskap och ergonomi

Teknisk mekanik

Bearbetnings-, yt- och fogningsteknik

Strömningsmekanik och akustik

DOI

10.1115/1.4052705

Mer information

Skapat

2021-10-19