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Improvement of numerical simulation model setup and calculation time in additive manufacturing-laser-metal-deposition components with an advanced modelling strategy

: Biegler, Max; Khazan, Pavel; Gatzen, Marius; Rethmeier, Michael


Sommitsch, Christof (Ed.) ; TU Graz:
Mathematical modelling of weld phenomena 12 : Selected peer reviewed papers from the 12th International Seminar Numerical Analysis of Weldability; September 23-26, 2018, Graz, Schloss Seggau, Austria
Graz: Verlag der TU Graz, 2019
ISBN: 978-3-85125-615-4
ISBN: 978-3-85125-616-1
International Seminar Numerical Analysis of Weldability <12, 2018, Graz>
Bundesministerium fur Wirtschaft und Energie BMWi (Deutschland)
IGF; 18737 N; FOSTA
Bundesministerium für Bildung und Forschung BMBF (Deutschland)
Zwanzig20; 03ZZ0210J
Fraunhofer IPK ()

Rapid localized heating and cooling during additive manufacturing using laser deposition method (LMD) lead to loss of dimensional accuracy as well as cracking of built parts. Finite-Element welding simulations allow prediction of geometrical deviations and accumulated residual stresses as well as their optimization before conducting experiments. Due to the great length of stacked welds, calculation times for fully transient thermomechanical simulations are currently long, the calculation stability suffers from the high number of contact bodies in the model and the modelling effort is high, as the geometries need to be sliced and positioned layer-wise.
In this contribution, an integrated modelling approach is demonstrated for a thin-walled LMD component made from 30 layers of 1.4404 (316L) stainless steel: Instead of the layer-by-layer modelling strategy commonly found in the literature, the whole component mesh is kept in one piece and the fully transient, layer-by-layer material deposition is implemented via element sets. In contrast to prior simulations, nonlinear contact between the layers does not have to be considered, significantly decreasing calculation times. The calculated distortions are compared to recently published, in-situ digital image correlation (DIC) measurements as well as numerical simulations conducted with the established layer-wise modelling strategy to judge result quality. Finally, the improvement in calculation time and ease-of-use is compared between both modelling approaches and conclusions regarding future usage for industrial-scale components are drawn