Finite element modeling of thermal behavior of molten pool in closed-loop controlled laser-based additive manufacturing

2002 ◽  
Author(s):  
Dongming Hu ◽  
Radovan Kovacevic
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Thermal Behavior ◽  
Finite Element Modeling ◽  
Molten Pool ◽  
Closed Loop ◽  
Element Modeling

Closed-Loop High-Fidelity Simulation Integrating Finite Element Modeling With Feedback Controls in Additive Manufacturing

2020 ◽  
Vol 143 (2) ◽  
Author(s):  
Dan Wang ◽  
Xu Chen
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Finite Element Modeling ◽  
Closed Loop ◽  
Agile Manufacturing ◽  
High Fidelity ◽  
Feedback Controls ◽  
Element Modeling ◽  
Melt Pool ◽  
Wide Range

Abstract A high-precision additive manufacturing (AM) process, powder bed fusion (PBF) has enabled unmatched agile manufacturing of a wide range of products from engine components to medical implants. While finite element modeling and closed-loop control have been identified key for predicting and engineering part qualities in PBF, existing results in each realm are developed in opposite computational architectures wildly different in time scale. This paper builds a first-instance closed-loop simulation framework by integrating high-fidelity finite element modeling with feedback controls originally developed for general mechatronics systems. By utilizing the output signals (e.g., melt pool width) retrieved from the finite element model (FEM) to update directly the control signals (e.g., laser power) sent to the model, the proposed closed-loop framework enables testing the limits of advanced controls in PBF and surveying the parameter space fully to generate more predictable part qualities. Along the course of formulating the framework, we verify the FEM by comparing its results with experimental and analytical solutions and then use the FEM to understand the melt-pool evolution induced by the in- and cross-layer thermomechanical interactions. From there, we build a repetitive control (RC) algorithm to attenuate variations of the melt pool width.

Closed-Loop Simulation Integrating Finite Element Modeling With Feedback Controls in Powder Bed Fusion Additive Manufacturing

2020 ◽  
Author(s):  
Dan Wang ◽  
Xu Chen
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Finite Element Modeling ◽  
Closed Loop ◽  
Agile Manufacturing ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Element Modeling ◽  
Melt Pool ◽  
Wide Range

Abstract Powder bed fusion (PBF) additive manufacturing has enabled unmatched agile manufacturing of a wide range of products from engine components to medical implants. While high-fidelity finite element modeling and feedback control have been identified key for predicting and engineering part qualities in PBF, existing results in each realm are developed in opposite computational architectures wildly different in time scale. Integrating both realms, this paper builds a first-instance closed-loop simulation framework by utilizing the output signals retrieved from the finite element model (FEM) to directly update the control signals sent to the model. The proposed closed-loop simulation enables testing the limits of advanced controls in PBF and surveying the parameter space fully to generate more predictable part qualities. Along the course of formulating the framework, we verify the FEM by comparing its results with experimental and analytical solutions and then use the FEM to understand the melt-pool evolution induced by the in-layer thermomechanical interactions. From there, we build a repetitive control algorithm to greatly attenuate variations of the melt pool width.

Closed‐loop finite‐element modeling of smart structures—An overview

1999 ◽  
Vol 105 (2) ◽  
pp. 1239-1240
Author(s):  
Vasundara V. Varadan ◽  
Young‐hun Lim ◽  
Senthil V. Gopinathan ◽  
Vijay K. Varadan
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Closed Loop ◽  
Smart Structures ◽  
Element Modeling

Finite Element Modeling for Optimizing Hermetic Package Reliability

1989 ◽  
Vol 111 (4) ◽  
pp. 255-260 ◽  
Author(s):  
J. H. Lau ◽  
L. B. Lian-Mueller
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Optimal Design ◽  
Thermal Behavior ◽  
Finite Element Modeling ◽  
Thermal Stresses ◽  
Finite Element Models ◽  
The Finite Element Method ◽  
Element Modeling ◽  
Package Reliability

The thermal stresses in microwave packages are studied by the finite element method. Emphasis is placed on the effects of material construction and design on the reliability of very small hermetic packages. Three different microwave packages have been designed and six finite element models (two for each design) have been analyzed. To verify the validity of the finite element results, some leak tests have been performed and the results agree with the analytical conclusions. The results presented herein should provide a better understanding of the thermal behavior of hermetic packages and should be useful for their optimal design.

Modelling and measuring the thermal behaviour of the molten pool in closed-loop controlled laser-based additive manufacturing

2003 ◽  
Vol 217 (4) ◽  
pp. 441-452 ◽  
Author(s):  
D Hu ◽  
R Kovacevic
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Thermal Behaviour ◽  
Molten Pool ◽  
Closed Loop ◽  
Three Dimensional ◽  
Infrared Camera ◽  
Element Model ◽  
Experimental Investigations ◽  
Process Conditions

Laser-based additive manufacturing (LBAM) is a promising manufacturing technology that can be widely applied in solid freeform fabrication (SFF), component recovery and regeneration, and surface modification. The thermal behaviour of the molten pool is one of the critical factors that influences laser deposition indices such as geometrical accuracy, material properties and residual stresses. In this paper, a three-dimensional finite element model is developed using ANSYS to simulate the thermal behaviour of the molten pool in building a single-bead wall via a closed-loop controlled LBAM process in which the laser power is controlled to keep the width of the molten pool constant. The temperature distribution, the geometrical feature of the molten pool and the cooling rate under different process conditions are investigated. To verify the simulation results, the thermal behaviour of the molten pool is measured by a coaxially installed infrared camera in experimental investigations of a closed-loop controlled LBAM process. Results from finite element thermal analysis provide guidance for the process parameter selection in LBAM, and develop a base for further residual stress analysis.

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