Anders Snis

Galati Manuela

Luca Iuliano

English

PORTO@iris (Publications Open Repository TOrino - Politecnico di Torino)

Three-dimensional thermomechanical simulation of Electron Beam Melting processes for the melt pool geometry predictionManuela Galati 1*, Luca Iuliano 1, Anders Snis 2(1) Department of Management and Production Engineering (DIGEP)Politecnico di Torino, Corso Duca Degli Abruzzi 24, I-10129 Torino, Italy(2) Arcam AB, Krokslätts Fabriker 27A, SE-431 37 Mölndal, Swedene-mail: manuela.galati@polito.it Due to the complexity of the physics, many finite element models presented in the literature for Electron Beam Melting simulations are considering thermal aspects only [1]. However, heat transfer may be affected by the change of the material properties during the melting and the cooling phases. Therefore, uncouple thermal models may not be well adapted for predicting the temperature distribution of the melt zone, and thus they may not be able to realistically calculate for instance melt depths and melt widths.In this work, an improved but still rather simple computational analysis is presented for a more detailed prediction of heat transfer and melting pool geometries in the Electron Beam Melting process simulations. In particular, the work presents an up-to-date three-dimensional numerical local-scale model for a coupled thermo-mechanical analysis based on a numerical approach recently developed [2]. Nonlinearities due to the variation of material properties when the material melts are considered in the analysis. Particularly, temperature dependent mechanical coefficients are used to account for physical aspects such as: solid phase transformation, powder layer shrinkage during melting, thermal expansion and shrinkage of solid material during heating and cooling, and stress formation within the solid material. Representative simulations of single line melt tracks are performed, and a comparison between uncoupled thermal model, coupled thermo-mechanical model and experiments is carried out.Figure 1: Cross section of the melted track: simulated (left) experimental (left)[1] M Galati and L Iuliano (2017) A literature review of powder-based electron beam melting focusing on numerical simulations. Additive Manufacturing.[2] M Galati, L Iuliano, A Salmi and E Atzeni (2017) Modelling energy source and powder properties for the development of a thermal FE model of the EBM additive manufacturing process. Additive Manufacturing. Vol(14), 49-59. 

Three-dimensional thermomechanical simulation of Electron Beam Melting processes for the melt pool geometry prediction

https://iris.polito.it/bitstream/11583/2707145/1/Galati_Three-dimensional%20thermomechanical%20simulation%20of%20Electron%20Beam%20Melting%20processes%20for%20the%20melt%20pool%20geometry%20prediction.doc

Three-dimensional thermomechanical simulation of Electron Beam Melting processes for the melt pool geometry prediction

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