Finite element analysis of single layer forming on metallic powder bed in rapid prototyping by selective laser processing

Matsumoto, Mitsunobu; Shiomi, Masanori; Osakada, Kozo; Abe, Fumie

doi:10.1016/s0890-6955(01)00093-1

Cited by 275 publications

(134 citation statements)

References 5 publications

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“…An understanding of thermal transient and residual stresses, and also the influence of changes in process parameters on generation of these stresses, is required for development of a reliable MMLD process for dental restorations. FE analysis has provided substantial insights into the development of the temperature gradients, as well as thermal resistant and residual stresses involved in the conversion of a powder bed to a dense body [21][22][23][24][25]. Warpage of the fabricated multimaterial components has also been studied using FE-based modelling.…”

Section: Introductionmentioning

confidence: 99%

Powder bed generation in integrated modelling of additive layer manufacturing of orthopaedic implants

Krzyżanowski

Svyetlichnyy

Stevenson

et al. 2016

Int J Adv Manuf Technol

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This paper presents an original model of powder bed generation developed within the frame of an integrated modelling approach for studying the interaction of physical mechanisms in additive layer manufacturing (ALM) of orthopaedic implants. The model is based on cellular automata (CA) approach and describes the relationship between moving particles of different sizes during deposition on a surface in three dimensions. The surface is defined by the horizontal two-dimensional CA on which particles fall and irreversibly stick to a growing deposit. The model allows for consideration of different restructuring cases when particles are allowed to rotate as often as necessary until achievement of a local minimum position. Changes in the packing density of the powder bed have been investigated numerically depending on technological parameters, such as particle size distribution, deposition rate and sequence of powder deposition. The model has been developed with the aim of merging to the finite element (FE)-based integrated model and is applicable to a different ranges of materials including metals and also non-metals.

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Section: Introductionmentioning

confidence: 99%

Powder bed generation in integrated modelling of additive layer manufacturing of orthopaedic implants

Krzyżanowski

Svyetlichnyy

Stevenson

et al. 2016

Int J Adv Manuf Technol

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“…Several published studies explicitly described the specific mechanics of the stress formulation as described above, most notably in the works of Mercelis and Kruth [9] and Knowles et al [8]. Other studies which discussed this issue in depth were those by Roberts et al [16][17], Matsumoto et al [18], Gu et al [19], Guo and Leu [4], and Van Belle et al [20].…”

Section: Figure 1 Slm/dmls Process Mechanicsmentioning

confidence: 99%

“…The earliest examples of a stress model for SLM/DMLS were developed by Matsumoto et al [18,55] Belgium have also worked extensively on this problem [9, 32, 37-39, [56][57][58] and over time developed one of the most well-respected general SLM/DMLS models in the world, as discussed previously.…”

Section: Stress and Distortion 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%

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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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“…Nevertheless, they were not concerned with the effects of substrate on the microstructure and performances of formed components. In addition, most researchers pay more attention to the numerical modeling of the thermo-mechanical behavior during the laser additive manufacturing process, but not focus on the influences of substrate temperature on this heat history [15][16][17][18][19]5]. In this work, combined with the numerical simulation model, the LMDS system and a self-developed substrate preheating facility were employed to intensively investigate the effects of substrate preheating on the as-deposited metal parts.…”

Section: Introductionmentioning

confidence: 99%

Effects of substrate preheating on the thin-wall part built by laser metal deposition shaping

Zhang

Wang

Liu

et al. 2014

Applied Surface Science

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Finite element analysis of single layer forming on metallic powder bed in rapid prototyping by selective laser processing

Cited by 275 publications

References 5 publications

Powder bed generation in integrated modelling of additive layer manufacturing of orthopaedic implants

Powder bed generation in integrated modelling of additive layer manufacturing of orthopaedic implants

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

Effects of substrate preheating on the thin-wall part built by laser metal deposition shaping

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