Numerical modelling of heat transfer and experimental validation in powder-bed fusion with the virtual domain approximation

Eric Neiva, Michele Chiumenti, Miguel Cervera, Emilio Salsi, Gabriele Piscopo, Santiago Badia, Alberto F. Martín, Zhuoer Chen, Caroline Lee, Christopher Davies

Research output: Contribution to journalArticleResearchpeer-review

1 Citation (Scopus)

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.

Original languageEnglish
Article number103343
Number of pages17
JournalFinite Elements in Analysis and Design
Volume168
DOIs
Publication statusPublished - Jan 2020

Keywords

  • Additive manufacturing (AM)
  • Finite elements (FE)
  • High performance computing (HPC)
  • Powder-bed fusion (PBF)
  • Selective laser melting (SLM)
  • Thermal analysis

Cite this

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title = "Numerical modelling of heat transfer and experimental validation in powder-bed fusion with the virtual domain approximation",
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.",
keywords = "Additive manufacturing (AM), Finite elements (FE), High performance computing (HPC), Powder-bed fusion (PBF), Selective laser melting (SLM), Thermal analysis",
author = "Eric Neiva and Michele Chiumenti and Miguel Cervera and Emilio Salsi and Gabriele Piscopo and Santiago Badia and Mart{\'i}n, {Alberto F.} and Zhuoer Chen and Caroline Lee and Christopher Davies",
year = "2020",
month = "1",
doi = "10.1016/j.finel.2019.103343",
language = "English",
volume = "168",
journal = "Finite Elements in Analysis and Design",
issn = "0168-874X",
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Numerical modelling of heat transfer and experimental validation in powder-bed fusion with the virtual domain approximation. / Neiva, Eric; Chiumenti, Michele; Cervera, Miguel; Salsi, Emilio; Piscopo, Gabriele; Badia, Santiago; Martín, Alberto F.; Chen, Zhuoer; Lee, Caroline; Davies, Christopher.

In: Finite Elements in Analysis and Design, Vol. 168, 103343, 01.2020.

Research output: Contribution to journalArticleResearchpeer-review

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AU - Neiva, Eric

AU - Chiumenti, Michele

AU - Cervera, Miguel

AU - Salsi, Emilio

AU - Piscopo, Gabriele

AU - Badia, Santiago

AU - Martín, Alberto F.

AU - Chen, Zhuoer

AU - Lee, Caroline

AU - Davies, Christopher

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AB - 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.

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