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A coupled fluid-mechanical workflow to simulate the directed energy deposition additive manufacturing process
Computational Mechanics ( IF 4.1 ) Pub Date : 2021-03-11 , DOI: 10.1007/s00466-020-01960-9
Lauren L. Beghini , Michael Stender , Daniel Moser , Bradley L. Trembacki , Michael G. Veilleux , Kurtis R. Ford

Simulation of additive manufacturing processes can provide essential insight into material behavior, residual stress, and ultimately, the performance of additively manufactured parts. In this work, we describe a new simulation based workflow utilizing both solid mechanics and fluid mechanics based formulations within the finite element software package SIERRA (Sierra Solid Mechanics Team in Sierra/SolidMechanics 4.52 User’s Guide SAND2019-2715. Technical report, Sandia National Laboratories, 2011) to enable integrated simulations of directed energy deposition (DED) additive manufacturing processes. In this methodology, a high-fidelity fluid mechanics based model of additive manufacturing is employed as the first step in a simulation workflow. This fluid model uses a level set field to track the location of the boundary between the solid material and background gas and precisely predicts temperatures and material deposition shapes from additive manufacturing process parameters. The resulting deposition shape and temperature field from the fluid model are then mapped into a solid mechanics formulation to provide a more accurate surface topology for radiation and convection boundary conditions and a prescribed temperature field. Solid mechanics simulations are then conducted to predict the evolution of material stresses and microstructure within a part. By combining thermal history and deposition shape from fluid mechanics with residual stress and material property evolutions from solid mechanics, additional fidelity and precision are incorporated into additive manufacturing process simulations providing new insight into complex DED builds.



中文翻译:

耦合的流体力学工作流程,可模拟定向能量沉积添加剂的制造过程

增材制造过程的仿真可以提供有关材料性能,残余应力以及最终增材制造零件性能的基本信息。在这项工作中,我们将在有限元软件包SIERRA(Sierra / SolidMechanics 4.52用户指南SAND2019-2715中的Sierra固体力学团队,SAND2019-2715。技术报告,桑迪亚国家实验室, 2011年),以实现对定向能量沉积(DED)增材制造工艺的集成模拟。在这种方法中,将基于高保真流体力学的增材制造模型用作模拟工作流程的第一步。该流体模型使用一个水平集字段来跟踪固体材料和背景气体之间边界的位置,并根据增材制造工艺参数精确预测温度和材料沉积形状。然后将从流体模型中得到的沉积形状和温度场映射到固体力学公式中,以为辐射和对流边界条件以及指定的温度场提供更准确的表面拓扑。然后进行固体力学模拟,以预测零件内材料应力和微观结构的演变。通过将流体力学的热历史和沉积形状与固体力学的残余应力和材料性能演变结合起来,

更新日期:2021-03-11
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