Selective electron beam melting of Ti-6Al-4V is a promising additive manufacturing process to produce complex parts layer-by-layer additively. The quality and dimensional accuracy of the produced parts depend on various process parameters and their interactions. In the present contribution, the lifetime, width and depth of the pools of molten powder material are analyzed for different beam powers, scan speeds and line energies in experiments and simulations. In the experiments, thin-walled structures are built with an ARCAM AB A2 selective electron beam melting machine and for the simulations a thermal finite element simulation tool is used, which is developed by the authors to simulate the temperature distribution in the selective electron beam melting process. The experimental and numerical results are compared and a good agreement is observed. The lifetime of the melt pool increases linearly with the line energy, whereby the melt pool dimensions show a nonlinear relation with the line energy.
The present contribution is concerned with the macroscopic modelling of the selective beam melting process by using finite elements. In this context the objective is to detail a continuum model to describe the process. Furthermore two different solution approaches are applied to the model and compared in terms of performance. An adaptive mesh refinement strategy is also demonstrated to increase the quality of the solution in the vicinity of the beam.
In the present contribution the temperature distribution in the selective beam melting process for polymer materials is simulated to better understand the influence of process parameters on the properties of the produced part. The basis for the developed simulation tool is the nonlinear heat equation including temperature dependent functions for the heat capacity and the heat conduction which were obtained by experimental measurements. The effect of latent heat occurring in the process is also taken into account. The heat equation is discretized in time and space where a Runge-Kutta method of Radau IIA type is used for time integration. An adaptive finite element method is applied for the discretization in space and the model is implemented into the finite element library deal.II. The heat and cooling rate as important process parameters are simulated for different beam velocities. The ability for computing these process parameters makes the simulation tool suited for optimizing the process management of selective beam melting plants.
In the present contribution a nonlinear thermomechanical finite element model with temperature dependent material parameters is used to simulate the electron beam melting process for TiAl6V4. The beam is modeled as a moving heat source and the isentropic split solution scheme is applied. The temperature and stress distribution during the process were simulated and showed sound results from a qualitative point of view.
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