Additive manufacturing is an appealing solution to produce geometrically complex parts, difficult to manufacture using traditional technologies. The extreme process conditions, in particular the high temperature, complex interactions and couplings, and rich metallurgical transformations that this process entails, are at the origin of numerous process defects. Therefore, the numerical simulation of the process is gaining the interest of both the scientific and the industrial communities. However, simulating that process demands impressive computational resources, limiting high resolution simulations to the microscopic and mesoscopic scales. This paper proposes a thermo-mechanical modeling framework at the process scale as well as its associated reduced order simulation counterpart, enabling the parametric evaluation of the part distortion. It deeply addresses the process calibration using a high-resolution computational procedure based on the use of an in-plane-out-of-plane separated representation at the heart of the so-called Proper Generalized Decomposition (PGD), as well as the analysis of the transient thermal effects, defining the conditions in which the thermal and mechanical analyses can be decoupled.

增材制造是一种吸引人的解决方案，用于生产几何形状复杂的零件，这些零件很难使用传统技术进行制造。极端的工艺条件，特别是高温，复杂的相互作用和偶合以及该工艺所需要的丰富的冶金转化，是许多工艺缺陷的根源。因此，该过程的数值模拟正在引起科学界和工业界的兴趣。但是，模拟该过程需要大量的计算资源，从而将高分辨率模拟限制在微观和介观尺度。本文提出了一种在过程规模上的热机械建模框架及其相关的降阶模拟副本，从而可以对零件变形进行参数评估。