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Published in: The International Journal of Advanced Manufacturing Technology 2/2024

07-03-2023 | ORIGINAL ARTICLE

Fast simulation for powder bed fusion process based on thermal field pattern repetitions: application on electron beam melting process

Authors: Yann Ledoux, Soukaina Ghaoui, Alex Ballu, Christelle Grandvallet, François Villeneuve, Matthieu Museau, Frederic Vignat, Thanh Hoang Vo

Published in: The International Journal of Advanced Manufacturing Technology | Issue 2/2024

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Abstract

This work addresses the fast macroscale modelling of powder bed fusion for metallic materials. The main available approaches are analysed and applied on a typical benchmark of overhang part made by electron beam melting process. The aim is to quantify the side loss geometrical defect of the part. The accuracy of such classical fast macroscale modelling is limited due to the simplifications on the beam motion (not addressed) and the none dependency of the material properties to the temperature. To overcome these limitations, an original fast simulation is developed based on identification of layer-by-layer sequence repetitions and resulting thermal fields. These fields are then directly introduced to a mechanical simulation through thermal curve. Comparison between various fast simulation approaches are made according to their abilities to simulate the geometrical part defects and their required computing times. The first results on the thermal curve simulation show a good balance between accuracy and speed up regarding the full thermomechanical simulation and the experimental defect obtained on the produced part.

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Metadata
Title
Fast simulation for powder bed fusion process based on thermal field pattern repetitions: application on electron beam melting process
Authors
Yann Ledoux
Soukaina Ghaoui
Alex Ballu
Christelle Grandvallet
François Villeneuve
Matthieu Museau
Frederic Vignat
Thanh Hoang Vo
Publication date
07-03-2023
Publisher
Springer London
Published in
The International Journal of Advanced Manufacturing Technology / Issue 2/2024
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI
https://doi.org/10.1007/s00170-023-11142-5

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