In selective laser melting (SLM), three-dimensional parts are build up from a metal powder bed by layer-wise melting with a laser. While SLM offers a high flexibility in geometrical design and material texture, the interplay of dozens of parameters is difficult to analyze experimentally. The current research focuses on numerical simulation to increase confidence in manufactured parts and to reduce the time to market. Using a smoothed particle hydrodynamics (SPH) implementation on GPU, the 3D melt pool dynamics in a single laser track can be simulated within less than 2 h with a reasonable spatial resolution of 3 \(\upmu \)m. This is an extreme speedup compared to concurrent CFD methods that have recently been applied to the same problem. Using a SPH implementation on GPU, the 3D melt pool dynamics in a single laser track can be simulated within less than an hour with a reasonable spatial resolution of 3 \(\upmu \)m. This is an extreme speedup compared to concurrent CFD methods that have recently been applied to the same problem. The computational efficiency allows to conduct parameter studies, which before were prohibitively expensive, to generate a virtual process. To make the simulations possible a curvature calculation technique was applied, which is novel in the field of SPH. Additionally the advantage of a direct description of the internal energy is outlined by comparing the approach with the commonly applied apparent heat approach. Designers may profit from the fast simulations in two different scenarios: firstly, through a direct numerical simulation of certain parameter combinations and scenarios and, secondly, by informing advanced surrogate models or part-scale models to predict the behavior of the entire part being produced. When adapting the heat source model, the SPH framework may also be used to describe the related electron beam melting process.

中文翻译：

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使用粉末级SPH模拟生成SLM的虚拟过程图

在选择性激光熔化（SLM）中，通过用激光逐层熔化从金属粉末床中建立三维零件。尽管SLM在几何设计和材料纹理方面提供了很高的灵活性，但数十个参数之间的相互作用很难通过实验进行分析。当前的研究集中在数值模拟上，以增加对制造零件的信心并缩短上市时间。使用GPU上的平滑粒子流体动力学（SPH）实现，可以在不到2 h的时间内以合理的3 \（\ upmu \）空间分辨率模拟单个激光轨道中的3D熔池动力学 米 与最近已应用于同一问题的并发CFD方法相比，这是极大的提速。通过在GPU上使用SPH实施，可以在不到一个小时的时间内以3 \（\ upmu \）的合理空间分辨率模拟单个激光轨道中的3D熔池动力学 米 与最近已应用于同一问题的并发CFD方法相比，这是极大的提速。计算效率允许进行参数研究，以生成虚拟过程，而以前这是非常昂贵的。为了使模拟成为可能，应用了曲率计算技术，这在SPH领域是新颖的。另外，通过将该方法与通常应用的视在热方法进行比较，可以概述直接描述内部能量的优点。设计人员可能会从两种不同情况下的快速仿真中受益：首先，通过对某些参数组合和方案进行直接数值模拟；其次，通过通知高级替代模型或零件比例模型来预测所生产整个零件的行为。