Scan pattern dependent (multi-track) residual stress buildup over multiple layers in the powder bed fusion process is governed by coupled thermo-mechanics. The high computational cost associated with these simulations has resulted in the general adoption of approximate computational methods. The numerical or thermo-mechanical accuracy of assumptions made in these computational methods is not fully characterized. If benchmark multi-track simulations for small size multi-layer parts are available, including temperatures, strain fields and deformation results, it will be possible to scientifically develop new approximation schemes or modify existing ones to improve their accuracy. Present work develops a suggestive benchmark using full multi-track thermomechanical simulations, with comparison to various approximate methods. The target configurations are simple prismatic geometries with 30 layers and up to 120 mm³ volume, illustrating the influence of domain size on the approximate results. Anticipating the future challenges of measuring stresses and deformation in these small benchmark geometries, an experimental setup based on sheet metal forming principals is demonstrated numerically. The proposed setup will provide a methodology to experimentally validate these benchmarks.

在粉末床熔合过程中，与扫描模式有关的（多迹线）残余应力在多层结构上的累积是由耦合热力学控制的。与这些模拟相关的高计算成本导致了近似计算方法的普遍采用。在这些计算方法中进行的假设的数值或热机械精度没有得到充分表征。如果可以获得用于小型多层零件的基准多轨仿真，包括温度，应变场和变形结果，则有可能科学地开发新的近似方案或修改现有的近似方案以提高其准确性。通过与多种近似方法进行比较，目前的工作使用完整的多轨热力学模拟方法开发了一个可参考的基准。³卷，说明域大小对近似结果的影响。预期在这些小的基准几何形状中测量应力和变形的未来挑战，在数值上证明了基于钣金成形原理的实验装置。提议的设置将提供一种通过实验验证这些基准的方法。