An innovative Fast Layer-wise Simulation of Temperature distribution using a Chessboard Strategy (FALS TECHS) in the powder-bed fusion process

SmartScan: An intelligent scanning approach for uniform thermal distribution, reduced residual stresses and deformations in PBF additive manufacturing

“…where Tr,avg(lp) is the average temperature of representation elements Tr(i,j,k,lp) at time lp and Tm is the melting temperature of the material. Note that the definition of R(lp) is altered slightly from that used in [19] by adopting the melting temperature of the material in the denominator, rather than the average temperature. A smaller value of R(lp) implies a more uniform temperature distribution.…”

“…Three common heuristic sequences, namely: Successive (i.e., 1, 2, 3, …, 100), Successive Chessboard (i.e., 1, 3, 5, …, 99, 2, 4, 6, …, 100), and LHI, are used as benchmarks to evaluate the proposed SmartScan approach. The LHI approach used in our numerical study is based on the tessellation algorithm proposed by Malekipour [19] because it provided an unambiguous description of its working principle and input variables, thus making it straightforward to be reproduced. The tessellation algorithm maximizes the pairwise Euclidean distance between the next island to be scanned and each of the already scanned islands (as shown in the color map of Fig.…”

“…Scan sequence in these examples could mean the order in which each line in the stripe pattern is scanned, or the order in which each island in the island pattern is scanned. Researchers have shown that scan sequence significantly affects temperature distribution, residual stresses and distortions in PBF [5,[18][19][20][21].…”

Optimization of Chessboard Scanning Strategy Using Genetic Algorithm in Multi-Laser Additive Manufacturing Process

“…In this section, we employ FALS TECHS, our simulation technique developed in ABAQUS for simulation of temperature distribution throughout the layers printed in the chessboard scanning strategy [14] to validate the effectiveness of the E-GAMP scanning strategy and compare its prediction of the temperature distribution with its counterpart from traditional successive scanning strategy. We model a simple rectangular cube to investigate the effects of different strategies.…”

“…This phenomenon indicates the higher chance of generation of heat accumulation zones during the ML-PBF process. In the FALS TECHS simulation [14], the temperature values in the legends (Figure 14) represent the average temperature of the islands and not the melt pool. The temperature variation along the reference path resulting from two and three lasers E-GAMP strategies (Figures 13.g, 13.h, 13.j, and 13.k) also shows the convergence of the temperature variations toward a plateau; however, due to the presence of printed islands adjacent to the selected path, the temperature gradient shows a higher temperature gradient at the selected moments.…”