Enabling Part-Scale Scanwise process simulation for predicting melt pool variation in LPBF by combining GPU-based Matrix-free FEM and adaptive Remeshing
This work proposes to combine matrix-free finite element modeling (FEM), adaptive remeshing, and graphical processing unit (GPU) computing to enable, for the first time, scanwise process simulation of the Laser Powder Bed Fusion (L-PBF) process with temperature-dependent thermophysical properties at...
| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2022-12-01
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| Series: | Additive Manufacturing Letters |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2772369022000251 |
| _version_ | 1811322039327260672 |
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| author | Alaa Olleak Florian Dugast Prajwal Bharadwaj Seth Strayer Shawn Hinnebusch Sneha Narra Albert C. To |
| author_facet | Alaa Olleak Florian Dugast Prajwal Bharadwaj Seth Strayer Shawn Hinnebusch Sneha Narra Albert C. To |
| author_sort | Alaa Olleak |
| collection | DOAJ |
| description | This work proposes to combine matrix-free finite element modeling (FEM), adaptive remeshing, and graphical processing unit (GPU) computing to enable, for the first time, scanwise process simulation of the Laser Powder Bed Fusion (L-PBF) process with temperature-dependent thermophysical properties at the part scale. Compared to the conventional FEM using the global stiffness approach and a uniform mesh running on 10 CPU cores, l-PBF process simulation based on the proposed methodology running on a GPU card with 5,120 Compute Unified Device Architecture (CUDA) cores enables a speedup of over 10,000x. This significant speedup facilitates detailed thermal history and melt pool geometry predictions at high resolution for centimeter-scale parts within days of computation time. Two parts consisting of various geometric features are simulated to reveal the effects of scan strategy and local geometry on melt pool size variation, which correlate well with melt pool and lack-of-fusion porosity measurements obtained via experiment. |
| first_indexed | 2024-04-13T13:28:11Z |
| format | Article |
| id | doaj.art-60570b619475412285944823c1a7e50e |
| institution | Directory Open Access Journal |
| issn | 2772-3690 |
| language | English |
| last_indexed | 2024-04-13T13:28:11Z |
| publishDate | 2022-12-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Additive Manufacturing Letters |
| spelling | doaj.art-60570b619475412285944823c1a7e50e2022-12-22T02:45:03ZengElsevierAdditive Manufacturing Letters2772-36902022-12-013100051Enabling Part-Scale Scanwise process simulation for predicting melt pool variation in LPBF by combining GPU-based Matrix-free FEM and adaptive RemeshingAlaa Olleak0Florian Dugast1Prajwal Bharadwaj2Seth Strayer3Shawn Hinnebusch4Sneha Narra5Albert C. To6Department of Mechanical Engineering and Materials Science, University of Pittsburgh, Pittsburgh, PA 15261Department of Mechanical Engineering and Materials Science, University of Pittsburgh, Pittsburgh, PA 15261Department of Mechanical Engineering, Worcester Polytechnic Institute, 100 Institute Road, Worcester, Massachusetts, 01609Department of Mechanical Engineering and Materials Science, University of Pittsburgh, Pittsburgh, PA 15261Department of Mechanical Engineering and Materials Science, University of Pittsburgh, Pittsburgh, PA 15261Department of Mechanical Engineering, Carnegie Mellon University, Pittsburgh, Pennsylvania, 15213Department of Mechanical Engineering and Materials Science, University of Pittsburgh, Pittsburgh, PA 15261; Corresponding author.This work proposes to combine matrix-free finite element modeling (FEM), adaptive remeshing, and graphical processing unit (GPU) computing to enable, for the first time, scanwise process simulation of the Laser Powder Bed Fusion (L-PBF) process with temperature-dependent thermophysical properties at the part scale. Compared to the conventional FEM using the global stiffness approach and a uniform mesh running on 10 CPU cores, l-PBF process simulation based on the proposed methodology running on a GPU card with 5,120 Compute Unified Device Architecture (CUDA) cores enables a speedup of over 10,000x. This significant speedup facilitates detailed thermal history and melt pool geometry predictions at high resolution for centimeter-scale parts within days of computation time. Two parts consisting of various geometric features are simulated to reveal the effects of scan strategy and local geometry on melt pool size variation, which correlate well with melt pool and lack-of-fusion porosity measurements obtained via experiment.http://www.sciencedirect.com/science/article/pii/S2772369022000251Laser Powder Bed Fusion (L-PBF)GPU ComputingProcess simulationGeometry effectsThermal historyAdaptive remeshing |
| spellingShingle | Alaa Olleak Florian Dugast Prajwal Bharadwaj Seth Strayer Shawn Hinnebusch Sneha Narra Albert C. To Enabling Part-Scale Scanwise process simulation for predicting melt pool variation in LPBF by combining GPU-based Matrix-free FEM and adaptive Remeshing Additive Manufacturing Letters Laser Powder Bed Fusion (L-PBF) GPU Computing Process simulation Geometry effects Thermal history Adaptive remeshing |
| title | Enabling Part-Scale Scanwise process simulation for predicting melt pool variation in LPBF by combining GPU-based Matrix-free FEM and adaptive Remeshing |
| title_full | Enabling Part-Scale Scanwise process simulation for predicting melt pool variation in LPBF by combining GPU-based Matrix-free FEM and adaptive Remeshing |
| title_fullStr | Enabling Part-Scale Scanwise process simulation for predicting melt pool variation in LPBF by combining GPU-based Matrix-free FEM and adaptive Remeshing |
| title_full_unstemmed | Enabling Part-Scale Scanwise process simulation for predicting melt pool variation in LPBF by combining GPU-based Matrix-free FEM and adaptive Remeshing |
| title_short | Enabling Part-Scale Scanwise process simulation for predicting melt pool variation in LPBF by combining GPU-based Matrix-free FEM and adaptive Remeshing |
| title_sort | enabling part scale scanwise process simulation for predicting melt pool variation in lpbf by combining gpu based matrix free fem and adaptive remeshing |
| topic | Laser Powder Bed Fusion (L-PBF) GPU Computing Process simulation Geometry effects Thermal history Adaptive remeshing |
| url | http://www.sciencedirect.com/science/article/pii/S2772369022000251 |
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