|About this Abstract
||Materials Science & Technology 2020
||Additive Manufacturing: Qualification and Certification
||Ensuring Build Quality thru Physics-based Support Design Optimization for Residual Stress
||Albert To, Lin Cheng, Qian Chen, Xuan Liang
|On-Site Speaker (Planned)
A new design optimization method based on fast process simulation is proposed for the design of support structure for reducing residual stress and distortion in laser powder bed fusion (LPBF) processed metallic components. First, a modified inherent strain method is proposed for fast prediction of the stress and deformation. Second, a projection scheme is proposed to map the domain of support structure for a given solid component, in which the minimum support area is found for the next step. Third, lattice structure topology optimization is applied to minimize the mass consumption of support structure subjected to yield stress constraints. This not only prevent failure of the LPBF builds by limiting the residual stress below the yield strength, but also reduce material required for support structure. Both numerical simulation and experiments prove that the proposed method can ensure success of metal LPBF builds.