Efficient Multiscale Prediction of Cantilever Distortion by Selective Laser Melting

Abstract

Large tensile residual stress is one major issue for metal components made by selective laser melting (SLM). Residual stress is induced by non-uniform heat input, which leads to part distortion and detrimentally affects product performance. The conventional single track simulation method is not feasible to predict the distortion of a macro part since it demands an exceedingly long computational time. The coupling multiphysics phenomenon during the SLM process further complicates this issue. In this study, a temperature-thread multiscale modeling approach has been developed to predict part distortion of a twin cantilever. An equivalent body heat flux calculated from the micro scan model was imported as the “temperature-thread” to the subsequent layer hatch model. Then the hatched layer with temperature field can be used as a basic unit to build up the macro part. The temperature history and residual stress fields during the SLM process were predicted. And the distortion of twin cantilever was calculated with a reasonable accuracy compared to the experimental data.Mechanical Engineerin