An adaptive smoothed particle hydrodynamics (SPH) scheme for efficient melt pool simulations in additive manufacturing

Lüthi, C.; Afrasiabi, Mohamadreza; Bambach, Markus

doi:10.1016/j.camwa.2023.03.003

Cited by 23 publications

(3 citation statements)

References 43 publications

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“…Note that for control design we limit our attention to 2D simulations due to the prohibitively high computational costs associated with 3D simulations. The efficient codes developed for powder-scale LPBF simulations, employing hundreds or thousands of CPU/GPU cores [36], [41], or adaptive resolutions [42], can take several hours to a few days to model a single powder layer of approximately 1 mm. This makes it impractical to perform complete 3D simulations of multilayer LPBF, even with the computing power available today.…”

Section: High-fidelity Multi-layer Lpbf Process Modelmentioning

confidence: 99%

In-layer Thermal Control of a Multi-layer Selective Laser Melting Process

Liao‐McPherson¹,

Balta²,

Wüest³

et al. 2022

2022 European Control Conference (ECC)

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Selective Laser Melting (SLM) is an additive manufacturing technology that builds three dimensional parts by melting layers of metal powder together with a laser that traces out a desired geometry. SLM is popular in industry, however the inherent melting and re-solidification of the metal during the process can, if left uncontrolled, cause excessive residual stress, porosity, and other defects in the final printed parts. This paper presents a control-oriented thermal model of a multilayer SLM process and proposes a structured model reduction methodology with an associated reduced order model based in-layer controller to track temperature references. Simulation studies demonstrate that the controller is able to prevent layerto-layer heat buildup and that good closed-loop performance is possible using relatively low-order models.

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Section: High-fidelity Multi-layer Lpbf Process Modelmentioning

confidence: 99%

In-layer Thermal Control of a Multi-layer Selective Laser Melting Process

Liao‐McPherson¹,

Balta²,

Wüest³

et al. 2022

2022 European Control Conference (ECC)

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“…Examples of this increasingly popular application of the SPH method can be found in the field of coastal engineering to model systems such as flooding coastal flows [5], collision of waves with coastal structures [6], wave interactions with breakwaters [7,8], and general fluid-structure interactions [9,10]. Apart from coastal engineering, other specific problems can utilise SPH simulations to achieve seamless treatments for free surfaces and large deformations such as fluid sloshing inside a fuel tank [11], oil flow inside a gearbox [12], dam-break flooding through a city [13], emergency aircraft landing [14], helicopter ditching [15], and additive manufacturing [16].…”

Section: Introductionmentioning

confidence: 99%

Exploration of Two Different Length Scale Refinement Strategies on the Application of SPH Simulations on 3D Free-surface Flows

Tran,

Roberts,

Hastie

2024

Preprint

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A length scale refinement study is a standard practice to ensure the independence of a numerical model on spatial approximations. For smoothed particle hydrodynamics (SPH), the process of length scale refinement study tends to be conducted based on experience. A challenge of defining a universal length scale refinement strategy is the existence of two length scales – particle spacing and smoothing length. Despite the challenge, further investigations of the impact of different refinement strategies should be continually conducted to improve the reliability of practical SPH applications on 3D free-surface flows. In this study, a conventional strategy and a novel coupled refinement strategy are used to investigate the convergence of SPH simulations for free-surface flows using a standard SPH scheme available in an open-source framework. The two case studies are a dam break flow and a lesser-known stable regime water flow inside a rotating drum with lifters. Validations are conducted using existing literature data for the dam break flow and laser Doppler velocimetry (LDV) measurements for the rotating drum flow. The investigation shows that the proposed coupled length scale refinement strategy does not offer a significant improvement for the SPH model of the dam break flow comparing to the conventional strategy. On the other hand, the stable regime rotating drum fluid flow shows that both refinement strategies are not sufficient to tackle SPH’s on-going fundamental challenge of accurately predicting the flow field of complex 3D turbulent flows with free surfaces.

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“…For example, the Smoothed Particle-Hydrodynamics (SPH) has already been extensively used to simulate the friction stir extrusion (FSE), a novel solid-phase processing technique that consolidates and extrudes metal powders (and other kinds of raw materials) into high-performance parts (Li et al ., 2022a, 2022b), the additive friction stir deposition (AFS-D) (Stubblefield et al ., 2021; Stubblefield et al. , 2022), the laser fusion additive manufacturing (Russell et al ., 2018), the selective laser melting process (Qiu et al ., 2021), which uses a laser to heat metal or alloy powders that melt and solidify into metal parts or melt pool simulations in laser powder bed fusion (LPBF) (Lüthi et al ., 2023).…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of the extrusion process of viscoplastic materials using a radial point interpolation method

Rodrigues,

Belinha,

Natal Jorge

2023

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PurposeFused Filament Fabrication (FFF) is an extrusion-based manufacturing process using fused thermoplastics. Despite its low cost, the FFF is not extensively used in high-value industrial sectors mainly due to parts' anisotropy (related to the deposition strategy) and residual stresses (caused by successive heating cycles). Thus, this study aims to investigate the process improvement and the optimization of the printed parts.Design/methodology/approachIn this work, a meshless technique – the Radial Point Interpolation Method (RPIM) – is used to numerically simulate the viscoplastic extrusion process – the initial phase of the FFF. Unlike the FEM, in meshless methods, there is no pre-established relationship between the nodes so the nodal mesh will not face mesh distortions and the discretization can easily be modified by adding or removing nodes from the initial nodal mesh. The accuracy of the obtained results highlights the importance of using meshless techniques in this field.FindingsMeshless methods show particular relevance in this topic since the nodes can be distributed to match the layer-by-layer growing condition of the printing process.Originality/valueUsing the flow formulation combined with the heat transfer formulation presented here for the first time within an in-house RPIM code, an algorithm is proposed, implemented and validated for benchmark examples.

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An adaptive smoothed particle hydrodynamics (SPH) scheme for efficient melt pool simulations in additive manufacturing

Cited by 23 publications

References 43 publications

In-layer Thermal Control of a Multi-layer Selective Laser Melting Process

In-layer Thermal Control of a Multi-layer Selective Laser Melting Process

Exploration of Two Different Length Scale Refinement Strategies on the Application of SPH Simulations on 3D Free-surface Flows

Numerical simulation of the extrusion process of viscoplastic materials using a radial point interpolation method

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