| Abstract Scope |
The widely applied thermo-mechanical model using the finite element method (FEM) leaves much to be improved due to their oversimplifications on material deposition, molten pool flow, etc. In this study, a high-fidelity modelling approach by linking the thermal-fluid and mechanical models is developed to predict the thermal stress for AM taking into account the influences of thermal-fluid flow. Profiting from the precise temperature profiles and melt track geometry extracted from the thermal-fluid model, this work aims at simulating the thermal stress distribution by involving physical changes in the AM process, e.g., melting and solidification of powder particles, molten pool evolution and inter-track inter-layer re-melting. The thermal stress evolution in the AM process of single track, multiple tracks and multiple layers are simulated, where the rough surfaces and internal voids can be well incorporated. With the application of the data-driven prognostic model, the computational cost can be greatly reduced. |