A comprehensive study on thermal modeling of SLM process under conduction mode using FEM

Papazoglou, Emmanouil L.; Karkalos, Nikolaos E.; Markopoulos, Angelos P.

doi:10.1007/s00170-020-06294-7

Cited by 21 publications

(5 citation statements)

References 54 publications

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“…Conversely, although not ideal for particle simulation, mesh-based methods are more suitable for simulating other process steps. For example, the finite element method (FEM) has been extensively used to simulate the SLS process [11][12][13] due to its simplicity, efficiency and the vast available literature on the topic. The finite volume method (FVM) is also employed because of its conservative nature, helping to surpass some limitations present in the FEM [14].…”

Section: State Of the Artmentioning

confidence: 99%

Computational Framework to Model the Selective Laser Sintering Process

Castro,

Nóbrega,

Costa

2024

Materials

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Selective laser sintering (SLS) is one of the most well-regarded additive manufacturing (AM) sub-processes, whose popularity has been increasing among numerous critical and demanding industries due to its capabilities, mainly manufacturing parts with highly complex geometries and desirable mechanical properties, with potential to replace other, more expensive, conventional processes. However, due to its various underlying multi-physics phenomena, the intrinsic complexity of the SLS process often hampers its industrial implementation. Such limitation has motivated academic interest in obtaining better insights into the process to optimize it and attain the required standards. In that regard, the usual experimental optimization methods are time-consuming and expensive and can fail to provide the optimal configurations, leading researchers to resort to computational modeling to better understand the process. The main objective of the present work is to develop a computational model capable of simulating the SLS process for polymeric applications, within an open-source framework, at a particle-length scale to assess the main process parameters’ impact. Following previous developments, virgin and used polymer granules with different viscosities are implemented to better represent the actual process feedstock. The results obtained agree with the available experimental data, leading to a powerful tool to study, in greater detail, the SLS process and its physical parameters and material properties, contributing to its optimization.

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Section: State Of the Artmentioning

confidence: 99%

Computational Framework to Model the Selective Laser Sintering Process

Castro,

Nóbrega,

Costa

2024

Materials

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“…The output heat fluxes occur mainly through convection and conduction and also due to material ablation and radiation losses. Considering that, the energy conservation equation is given by [28]:…”

Section: Thermal Modelmentioning

confidence: 99%

“…From Section 2.4.1.1, it is known that the types of laser beams employed into SLS processes have a Gaussian intensity profile and a circular shape, hence only the radius being mentioned as a parameter. When treated as a surface heat source, following such conditions, the power intensity of the laser 𝑄 LB can be expressed as [28]:…”

Section: Laser Beammentioning

confidence: 99%

“…Most works on the simulation of SLS processes only consider the temperature profiles, sintering depth and phase change, whereas mass transfer is neglected [28]. However, sometimes researchers want to study the sintering evolution between scanned particles or, in the case of SLM, motion effects caused by differences in density in the liquid phase.…”

Section: Linear Momentummentioning

confidence: 99%

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Computational modelling of the selective laser sintering process

Castro¹,

Nóbrega²,

Costa³

2023

AIP Conference Proceedings

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The present work is a culmination of a five years journey from which I leave a better and wiser person, so, before advancing, I could not fail to thank those who contributed to mine and this work development.I would like to start by thanking my professor and supervisor João Miguel Nóbrega for introducing and teaching me computational mechanics, igniting a flame of curiosity and interest that illuminated this work. I would also like to extend my thanks to my second supervisor, Ricardo Costa, who, despite only meeting at the end of my academic path, greatly contributed to the development of my Master's Dissertation. It is a certainty that both their insights and knowledge on the work's subject steered me through it and, without any doubt, allowed its completion.

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“…This work aims to present a benchmarking study between the Lagamine code and the COMSOL Multiphysics® software (Comsol), one of the most commonly used commercial FE software for modeling the design and processes, in particular for thermal analysis in AM processes (Benarji et al, 2020;Courtois et al, 2014;Le et al, 2019;Scipioni Bertoli et al, 2017;Tran & Lo, 2018). Besides, it has been shown that the investigation of physical phenomena resulting from an AM process, as well as the associated mechanical and structural behaviors at different scales, is governed by thermal analysis (Ahn, 2021;Papazoglou et al, 2020). Therefore, a standard NAFEMS benchmark for thermal convection was first investigated.…”

Section: Introductionmentioning

confidence: 99%

Benchmarking study between Lagamine and Comsol Solvers for Finite Element Thermal Analyses of Directed Energy Deposition Process

2023

EJS

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This work presents a benchmarking study between Lagamine, an in-house developed finite element (FE) code, and COMSOL Multiphysics® (Comsol) commercial software in thermal analyses to investigate their capability in modeling complex manufacturing processes. For this purpose, two case studies, including a NAFEMS benchmark for heat transfer with convection and a Directed Energy Deposition (DED) of a bulk sample, were used as test cases. The simulation models using Lagamine and Comsol solvers for each case were described. The underlying algorithms and theories, as well as the software development, are investigated. The computational results indicate slight differences between Lagamine and Comsol solutions in both case studies. For the NAFEMS test case, the results obtained with the Comsol solver appear to be less dependent on the mesh size than those obtained with Lagamine. For the DED test case, within the chosen configurations of Lagamine and Comsol codes, the maximum difference in the highest peak temperatures obtained from the two codes is about 20%. From an engineering point of view, it is suggested to determine the parameters of the FE model consistently with the selected FE code to provide the best match with experimental observations.

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A comprehensive study on thermal modeling of SLM process under conduction mode using FEM

Cited by 21 publications

References 54 publications

Computational Framework to Model the Selective Laser Sintering Process

Computational Framework to Model the Selective Laser Sintering Process

Computational modelling of the selective laser sintering process

Benchmarking study between Lagamine and Comsol Solvers for Finite Element Thermal Analyses of Directed Energy Deposition Process

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