Numerical Modeling of Distortion of Ti-6Al-4V Components Manufactured Using Laser Powder Bed Fusion
The laser powder bed fusion (L-PBF) process is a powder-based additive manufacturing process that can manufacture complex metallic components. However, when the metallic components are fabricated with the L-PBF process, they frequently encounter the residual stress and distortion that occurs due to...
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| Format: | Article |
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MDPI AG
2022-09-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/12/9/1484 |
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| author | Patiparn Ninpetch Pruet Kowitwarangkul Prasert Chalermkarnnon Patcharapit Promoppatum Piyapat Chuchuay Phadungsak Rattanadecho |
| author_facet | Patiparn Ninpetch Pruet Kowitwarangkul Prasert Chalermkarnnon Patcharapit Promoppatum Piyapat Chuchuay Phadungsak Rattanadecho |
| author_sort | Patiparn Ninpetch |
| collection | DOAJ |
| description | The laser powder bed fusion (L-PBF) process is a powder-based additive manufacturing process that can manufacture complex metallic components. However, when the metallic components are fabricated with the L-PBF process, they frequently encounter the residual stress and distortion that occurs due to the cyclic of rapid heating and cooling. The distortion detrimentally impacts the dimensional and geometrical accuracy of final built parts in the L-PBF process. The purpose of this research was to explore and predict the distortion of Ti-6Al-4V components manufactured using the L-PBF process by using numerical modeling in Simufact Additive 2020 FP1 software. Firstly, the numerical model validation was conducted with the twin-cantilever beam part. Later, studies were carried out to examine the effect of component sizes and support-structure designs on the distortion of tibial component produced by the L-PBF process. The results of this research revealed a good agreement between the numerical model and experiment data. In addition, the platform was extended to predict the distortion in the tibial component. Large distortion arose near the interface between the tibial tray and support structure due to the different stiffness between the solid bulk and support structure. The distortion of the tibial component increased with increasing component size according to the surface area of the tibial tray, and with increasing thickness of the tibial tray. Furthermore, the support-structure design plays an important role in distortion reduction in the L-PBF process. For example, the maximum distortion of the tibial component was minimized up to 44% when a block support-structure design with a height of 2.5 mm was used instead of the lattice-based support. The present study provides useful information to help the medical sector to manufacture effective medical components and reduce the chance of part failure from cracking in the L-PBF process. |
| first_indexed | 2024-03-09T23:09:45Z |
| format | Article |
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| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-09T23:09:45Z |
| publishDate | 2022-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-6490a8f06a4640f38e1d7fea049ffddc2023-11-23T17:46:51ZengMDPI AGMetals2075-47012022-09-01129148410.3390/met12091484Numerical Modeling of Distortion of Ti-6Al-4V Components Manufactured Using Laser Powder Bed FusionPatiparn Ninpetch0Pruet Kowitwarangkul1Prasert Chalermkarnnon2Patcharapit Promoppatum3Piyapat Chuchuay4Phadungsak Rattanadecho5The Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut’s University of Technology North Bangkok (KMUTNB), Bangkok 10800, ThailandThe Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut’s University of Technology North Bangkok (KMUTNB), Bangkok 10800, ThailandAssistive Technology and Medical Devices Research Center, National Science and Technology Development Agency (NSTDA), Pathum Thani 12120, ThailandCenter for Lightweight Materials, Design, and Manufacturing, Department of Mechanical Engineering, Faculty of Engineering, King Mongkut’s University of Technology Thonburi (KMUTT), Bangkok 10140, ThailandThe Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut’s University of Technology North Bangkok (KMUTNB), Bangkok 10800, ThailandDepartment of Mechanical Engineering, Faculty of Engineering, Thammasat University (Rangsit Campus), Pathum Thani 12121, ThailandThe laser powder bed fusion (L-PBF) process is a powder-based additive manufacturing process that can manufacture complex metallic components. However, when the metallic components are fabricated with the L-PBF process, they frequently encounter the residual stress and distortion that occurs due to the cyclic of rapid heating and cooling. The distortion detrimentally impacts the dimensional and geometrical accuracy of final built parts in the L-PBF process. The purpose of this research was to explore and predict the distortion of Ti-6Al-4V components manufactured using the L-PBF process by using numerical modeling in Simufact Additive 2020 FP1 software. Firstly, the numerical model validation was conducted with the twin-cantilever beam part. Later, studies were carried out to examine the effect of component sizes and support-structure designs on the distortion of tibial component produced by the L-PBF process. The results of this research revealed a good agreement between the numerical model and experiment data. In addition, the platform was extended to predict the distortion in the tibial component. Large distortion arose near the interface between the tibial tray and support structure due to the different stiffness between the solid bulk and support structure. The distortion of the tibial component increased with increasing component size according to the surface area of the tibial tray, and with increasing thickness of the tibial tray. Furthermore, the support-structure design plays an important role in distortion reduction in the L-PBF process. For example, the maximum distortion of the tibial component was minimized up to 44% when a block support-structure design with a height of 2.5 mm was used instead of the lattice-based support. The present study provides useful information to help the medical sector to manufacture effective medical components and reduce the chance of part failure from cracking in the L-PBF process.https://www.mdpi.com/2075-4701/12/9/1484additive manufacturinglaser powder bed fusiontibial componenttitanium alloynumerical modelingdistortion |
| spellingShingle | Patiparn Ninpetch Pruet Kowitwarangkul Prasert Chalermkarnnon Patcharapit Promoppatum Piyapat Chuchuay Phadungsak Rattanadecho Numerical Modeling of Distortion of Ti-6Al-4V Components Manufactured Using Laser Powder Bed Fusion Metals additive manufacturing laser powder bed fusion tibial component titanium alloy numerical modeling distortion |
| title | Numerical Modeling of Distortion of Ti-6Al-4V Components Manufactured Using Laser Powder Bed Fusion |
| title_full | Numerical Modeling of Distortion of Ti-6Al-4V Components Manufactured Using Laser Powder Bed Fusion |
| title_fullStr | Numerical Modeling of Distortion of Ti-6Al-4V Components Manufactured Using Laser Powder Bed Fusion |
| title_full_unstemmed | Numerical Modeling of Distortion of Ti-6Al-4V Components Manufactured Using Laser Powder Bed Fusion |
| title_short | Numerical Modeling of Distortion of Ti-6Al-4V Components Manufactured Using Laser Powder Bed Fusion |
| title_sort | numerical modeling of distortion of ti 6al 4v components manufactured using laser powder bed fusion |
| topic | additive manufacturing laser powder bed fusion tibial component titanium alloy numerical modeling distortion |
| url | https://www.mdpi.com/2075-4701/12/9/1484 |
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