Simulation of Layer-by-Layer Selective Laser Melting Process with an Efficient Remeshing Technique

摘要

Quality and reliability of additively manufacturing (AM) parts using the selective laser melting (SLM) process are greatly influenced by the thermal history of the printing process. Prediction of parts thermal history using numerical methods, e.g. finite element (FE) method, can help reducing manufacturing defects, increasing process stability, improving design, and reducing cost and time required for the trial-and-error experimental approach. For the SLM process, finite element models are usually associated with simplifications (e.g., uniform heat flux and coarse mesh) that make the models computationally feasible but sacrifice model accuracy. This paper proposes a remeshing technique for the layer-by-layer SLM process simulation to reduce the computational expensiveness while maintaining high model accuracy. Transient thermal finite element models for small cubes are developed to predict the temperature history, melt pool size, and its variation throughout the building process for Ti-6Al-4V. Furthermore, temperature history at any location of the part can be easily obtained for detailed examination, if needed.