About this Abstract |
| Meeting |
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
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| Symposium
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2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
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| Presentation Title |
A FE Based Global-Submodel Simulation Approach for Shape Compensation and Predicting Failure in Metal Parts Fabricated by Laser Powder Bed Fusion |
| Author(s) |
Kaushik Das, Hongqing Sun, Geng Yun, Enqiang Lin, Reza Yavari, Anton Salem, Syed Zia Uddin, Nicholas Lajoie, Jack Jenny, Joseph Petsinger, Ethan Le |
| On-Site Speaker (Planned) |
Kaushik Das |
| Abstract Scope |
We present a two-stage print-simulation workflow. First, a rapid global analysis marches layer-by-layer on a voxel mesh using either thermo-mechanical or an inherent-strain method with elastic behavior. The resulting distortion field is mapped onto the triangulated solid to create a compensated geometry; surfaces are locally refined where distortion gradients spike, while top skins or other visually critical faces are left untouched to protect aesthetics.
Second, compact submodels are built only around high-strain regions. These use conformal hexahedral meshes, elastic-plastic laws, and a triaxiality-dependent ductile-failure metric to pinpoint crack nucleation. Displacement boundaries imported from the global run keep each submodel small yet deliver accurate local stress–strain histories. Monitoring strains at support–part interfaces lets us tune scan strategies so metal stays stiff during printing but detaches cleanly afterward.
The approach reproduces diverse defects—warping, thermal buckling, shrink lines—and correlates well with measured distortions, failure locations, and in-situ layer temperatures. |
| Proceedings Inclusion? |
Planned: Post-meeting proceedings |