Prediction of recoater crash in laser powder bed fusion additive manufacturing using graph theory thermomechanical modeling
Prediction of recoater crash in laser powder bed fusion additive manufacturing using graph theory thermomechanical modeling
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DOI：
10.1007/s40964-022-00331-5
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发表时间：
2022-08-05
影响因子：
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通讯作者：
Rao, Prahalada
中科院分区：
文献类型：
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作者：
Kobir, Md Humaun;Yavari, Reza;Rao, Prahalada
这项工作的目的是预测一种类型的热致工艺故障，称为重涂机崩溃，经常发生在激光粉末床熔融（LPBF）增材制造。快速准确的热机械模拟对于LPBF从业者识别和纠正可能导致重涂机崩溃的零件设计和加工条件中的潜在问题非常有价值。在这项工作中，为了预测重涂机碰撞（重涂机接触或影响）的可能性，我们开发并应用了一种基于图论的计算效率高的热机械建模方法。通过与非专有有限元分析（Abaqus）和专有LPBF模拟软件（Autodesk Netfabb）的比较，证明了该方法的准确性和计算效率。基于数值（验证）和实验（验证）研究，发现所提出的方法比非专有有限元建模快5至6倍，并且与商业仿真软件（Netfabb）具有相同的计算时间顺序，而不会牺牲预测精度。
The objective of this work is to predict a type of thermal-induced process failure called recoater crash that occurs frequently during laser powder bed fusion (LPBF) additive manufacturing. Rapid and accurate thermomechanical simulations are valuable for LPBF practitioners to identify and correct potential issues in the part design and processing conditions that may cause recoater crashes. In this work, to predict the likelihood of a recoater crash (recoater contact or impact) we develop and apply a computationally efficient thermomechanical modeling approach based on graph theory. The accuracy and computational efficiency of the approach is demonstrated by comparison with both non-proprietary finite element analysis (Abaqus), and a proprietary LPBF simulation software (Autodesk Netfabb). Based on both numerical (verification) and experimental (validation) studies, the proposed approach is found to be 5 to 6 times faster than the non-proprietary finite element modeling and has the same order of computational time as a commercial simulation software (Netfabb) without sacrificing prediction accuracy.