Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion
Abstract An efficient thermal-structural numerical solver for Additive Manufacturing has been developed based on a modified Lagrangian approach to solve the energy conservation equations in differential form. The heat transfer is modeled using the finite difference method applied to a deforming Lagr...
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| Format: | Article |
| Language: | English |
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Nature Portfolio
2023-10-01
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| Series: | Scientific Reports |
| Online Access: | https://doi.org/10.1038/s41598-023-43968-0 |
| _version_ | 1797453359272165376 |
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| author | Ilya Tsivilskiy Igor Shishkovsky |
| author_facet | Ilya Tsivilskiy Igor Shishkovsky |
| author_sort | Ilya Tsivilskiy |
| collection | DOAJ |
| description | Abstract An efficient thermal-structural numerical solver for Additive Manufacturing has been developed based on a modified Lagrangian approach to solve the energy conservation equations in differential form. The heat transfer is modeled using the finite difference method applied to a deforming Lagrangian mesh. The structural solver has been enhanced with the proposed effective quasi-elastic differential approach for modeling the elastoplastic behavior of materials. The algorithm is relatively simple to implement yet is highly effective. The solver can predict shape deformations of metal parts printed using the laser powder bed fusion technique. The second key capability of the solver is the auto-compensation of distortions of 3D-printed parts by proposing a corrected geometry of a surface to be printed, in order to ensure minimal deviation of the actual printed part from the desired one, even under non-optimal operating conditions or for complex shapes. All the simulation results have been verified in real-life experiments for 3D parts of sizes ranging from 10 to 15 mm up to 40 mm. |
| first_indexed | 2024-03-09T15:21:40Z |
| format | Article |
| id | doaj.art-aa17e130adfc4e16bc6f64ba32fd83aa |
| institution | Directory Open Access Journal |
| issn | 2045-2322 |
| language | English |
| last_indexed | 2024-03-09T15:21:40Z |
| publishDate | 2023-10-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj.art-aa17e130adfc4e16bc6f64ba32fd83aa2023-11-26T12:47:57ZengNature PortfolioScientific Reports2045-23222023-10-0113112710.1038/s41598-023-43968-0Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusionIlya Tsivilskiy0Igor Shishkovsky1Kazan Federal UniversityCenter for Materials Technologies, Skolkovo Institute of Science and TechnologyAbstract An efficient thermal-structural numerical solver for Additive Manufacturing has been developed based on a modified Lagrangian approach to solve the energy conservation equations in differential form. The heat transfer is modeled using the finite difference method applied to a deforming Lagrangian mesh. The structural solver has been enhanced with the proposed effective quasi-elastic differential approach for modeling the elastoplastic behavior of materials. The algorithm is relatively simple to implement yet is highly effective. The solver can predict shape deformations of metal parts printed using the laser powder bed fusion technique. The second key capability of the solver is the auto-compensation of distortions of 3D-printed parts by proposing a corrected geometry of a surface to be printed, in order to ensure minimal deviation of the actual printed part from the desired one, even under non-optimal operating conditions or for complex shapes. All the simulation results have been verified in real-life experiments for 3D parts of sizes ranging from 10 to 15 mm up to 40 mm.https://doi.org/10.1038/s41598-023-43968-0 |
| spellingShingle | Ilya Tsivilskiy Igor Shishkovsky Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion Scientific Reports |
| title | Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion |
| title_full | Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion |
| title_fullStr | Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion |
| title_full_unstemmed | Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion |
| title_short | Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion |
| title_sort | thermal structural hybrid lagrangian solver and numerical simulation based correction of shape deformation of stainless steel parts produced by laser powder bed fusion |
| url | https://doi.org/10.1038/s41598-023-43968-0 |
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