3D Finite Element Analysis in the selective laser melting process

Contuzzi, Nicola; Campanelli, Sabina Luisa; Ludovico, Antonio Domenico

doi:10.2507/ijsimm10(3)1.169

Cited by 100 publications

(53 citation statements)

References 10 publications

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“…The models produced by Huang et al [46], Li et al [47] and Kundakcioglu et al [48] are similar in nature to [45], but are more theoretically based, make fewer assumptions and heavily consider volume shrinkage and phase changes within the material. Coupled transient heat and mechanical analyses are used in these models.…”

Section: Temperature Distribution and Heat Transfer Modelsmentioning

confidence: 99%

“…The most widely-cited single layer stress models using finite element analysis are those developed by Hussein et al [21], Matsumoto et al [18], Contuzzi et al [45] and Dai and Gu [59]. Wu et al [60] proposed a model that analyzed the stresses within a single layer of powder as it solidifies, unlike the others, which were based on stresses within the solid materials.…”

Section: Stress and Distortion Modelsmentioning

confidence: 99%

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Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

2017

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Abstract:A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of the literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging and design-of-experiments), support structure optimization and overhang feature design; approximately 143 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs and potential future research directions are discussed in-depth in light of the present review.

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Section: Temperature Distribution and Heat Transfer Modelsmentioning

confidence: 99%

Section: Stress and Distortion Modelsmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

2017

View full text Add to dashboard Cite

show abstract

“…The models produced by Huang et al [46], Li et al [47], and Kundakcioglu et al [48] are similar in nature to [45], but are more theoretically-based, make fewer assumptions and heavily consider …”

Section: Temperature Distribution and Heat Transfer Modelsmentioning

confidence: 99%

“…The most widely cited single layer stress models using finite element analysis are those developed by Hussein et al [21], Matsumoto et al [18], Contuzzi et al [45], Dai & Gu [59]. Wu et al [60] proposed a model that analyzed the stresses within a single layer of powder as it solidifies, unlike the others, which were based on stresses within the solid materials.…”

Section: Stress and Distortion Modelsmentioning

confidence: 99%

“…Early research showed that the heat transfer was an unpredictable quantity in standard stress models, necessitating the development of complex heat transfer models. Many of the models deal with the temperature distribution and gradients within the material during processing using finite element analysis; the model, developed by Contuzzi et al [45] at the Polytechnic University of Bari in Italy, advanced a simple finite element analysis model to simulate the temperature distribution through the layers during the SLM process; stresses were not directly addressed in the model, but a stress model could easily be derived from the heat transfer model. The model also includes a method for directly modeling the phase change of the materials as the process is being run.…”

Section: Temperature Distribution and Heat Transfer Modelsmentioning

confidence: 99%

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Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Patterson¹,

Messimer²,

Farrington³

2017

Preprint

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A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce fulldensity metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

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Processes, Machines and Materials

2017

From Additive Manufacturing to 3d/4d Printing 1

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3D Finite Element Analysis in the selective laser melting process

Cited by 100 publications

References 10 publications

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Processes, Machines and Materials

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