Abstract 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.

中文翻译：

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基于虚拟域近似的粉末床熔合传热数值模拟和实验验证

摘要 在金属增材制造技术中，粉末床融合具有非常薄的层和快速的凝固速度，导致构建工作时间长和高度本地化的过程。许多努力致力于加快实际工业应用的仿真时间。这里建议的新方法，虚拟域近似，是在零件尺度的热有限元分析中域空间缩减的基于物理学的基本原理。除其他外，计算实验针对 647 层中 17.5 [cm3] 沉积体积的大型物理实验进行验证。对于这种复杂程度的快速自动参数估计，采用了高性能计算框架。它将专门的并行有限元软件 FEMPAR-AM 与 Dakota、用于参数化探索。与之前的最新技术相比，这种公式以相同的计算成本提供了更高的准确性。考虑到覆盖最后打印层的向上移动域，这为完全虚拟化模型设置了路径。