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A thermal multi-phase flow model for directed energy deposition processes via a moving signed distance function
Computer Methods in Applied Mechanics and Engineering ( IF 7.2 ) Pub Date : 2021-01-01 , DOI: 10.1016/j.cma.2020.113518
Ze Zhao , Qiming Zhu , Jinhui Yan

Abstract Thermal multi-phase flow analysis has been proven to be an indispensable tool in metal additive manufacturing (AM) modeling, yet accurate and efficient simulations of metal AM processes remains challenging. This paper presents a flexible and effective thermal multi-phase flow model for directed energy deposition (DED) processes. Departing from the data-fitted or presumed deposit shapes in the literature, we first derive a deposit geometry model based on an energy minimization problem with a mass conservation constraint. Then, an interface-capturing approach based on a signed distance function that moves with the laser is constructed to represent the air–metal interface evolution. The approach can be applied to any type of mesh without requiring the activation process of solid elements in a mesh. The coupled multi-phase Navier–Stokes and energy conservation equations are solved by a variational multi-scale formulation (VMS). A density-scaled continuous surface force (CSF) model is employed to incorporate the Marangoni effect, no penetration boundary condition, and the heat source on the air–metal interface. We utilize the proposed method to simulate two representative metal manufacturing problems. The simulated results are carefully compared with available experimental measurements and computational results from others. The results demonstrate the accuracy and modeling capabilities of the proposed method for metal AM problems.

中文翻译:

通过移动符号距离函数的定向能量沉积过程的热多相流模型

摘要 热多相流分析已被证明是金属增材制造 (AM) 建模中不可或缺的工具,但金属增材制造过程的准确高效模拟仍然具有挑战性。本文提出了一种用于定向能量沉积 (DED) 工艺的灵活有效的热多相流模型。与文献中数据拟合或假定的沉积物形状不同,我们首先基于具有质量守恒约束的能量最小化问题推导出沉积物几何模型。然后,构建了一种基于随激光移动的带符号距离函数的界面捕获方法来表示空气-金属界面的演变。该方法可以应用于任何类型的网格,而无需激活网格中的实体元素。耦合的多相纳维-斯托克斯方程和能量守恒方程通过变分多尺度公式 (VMS) 求解。采用密度缩放的连续表面力 (CSF) 模型来结合 Marangoni 效应、无渗透边界条件和空气-金属界面上的热源。我们利用所提出的方法来模拟两个有代表性的金属制造问题。模拟结果与其他可用的实验测量和计算结果进行了仔细比较。结果证明了所提出的方法对金属增材制造问题的准确性和建模能力。无渗透边界条件,热源在空气-金属界面。我们利用所提出的方法来模拟两个有代表性的金属制造问题。模拟结果与其他可用的实验测量和计算结果进行了仔细比较。结果证明了所提出的方法对金属增材制造问题的准确性和建模能力。无渗透边界条件,热源在空气-金属界面。我们利用所提出的方法来模拟两个有代表性的金属制造问题。模拟结果与其他可用的实验测量和计算结果进行了仔细比较。结果证明了所提出的方法对金属增材制造问题的准确性和建模能力。
更新日期:2021-01-01
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