A REVIEW OF THERMAL MODELLING FOR METAL ADDITIVE MANUFACTURING PROCESSES: BASIC ANALYTICAL MODELS TO STATE-OF-THE-ART SOFTWARE PACKAGES.

Research output: Contribution to conferencePaper

Abstract

This contribution will review computer modelling of metal Additive Manufacturing processes that involve a moving point heat source, with attention given to powder bed fusion . Modelling AM processes is important; because it allows AM practitioners to enhance understanding and will help improve the process at the planning stage of the manufacturing process. Full thermal modelling of PBF processes is a significant challenge but it will facilitate improved prediction of levels of porosity and the formation of microstructures. Thermal history of a part is the starting point for a residual stress analysis and therefore imperative. Advancements have been made in modelling approaches, evolving from Rosenthal’s basic analytical model progressing into Goldak’s continuum model. Initially considered in a welding context, these two basic models are adaptable and are commonly used for laser heating processes. DIABLO, a continuum thermomechanical model associated with the Lawrence Livermore National Laboratory, is reviewed. The significance of powder bed models and fluid flow in the melt pool, particularly Marangoni convection, will be investigated within the literature. Presently the market offers several commercial software packages for AM, including packages offered by ANSYS, COMSOL and MSC. State-of-the art software packages will be reviewed by comparing their specific claims and investigating those claims where possible.

Conference

ConferenceThe 35th International Manufacturing Conference
Abbreviated titleIMC35
CountryIreland
CityDublin
Period20/06/1820/06/18
Internet address

Fingerprint

manufacturing
software
metal
modeling
residual stress
stress analysis
welding
heat source
fluid flow
microstructure
laser
convection
porosity
state of the art
additive
melt
heating
market
history
prediction

Keywords

  • Additive Manufacturing
  • Powder Bed Fusion
  • Thermal Modelling
  • Simulation

Cite this

@conference{3953fb4fd7e14f919a454b67e35abc8d,
title = "A REVIEW OF THERMAL MODELLING FOR METAL ADDITIVE MANUFACTURING PROCESSES: BASIC ANALYTICAL MODELS TO STATE-OF-THE-ART SOFTWARE PACKAGES.",
abstract = "This contribution will review computer modelling of metal Additive Manufacturing processes that involve a moving point heat source, with attention given to powder bed fusion . Modelling AM processes is important; because it allows AM practitioners to enhance understanding and will help improve the process at the planning stage of the manufacturing process. Full thermal modelling of PBF processes is a significant challenge but it will facilitate improved prediction of levels of porosity and the formation of microstructures. Thermal history of a part is the starting point for a residual stress analysis and therefore imperative. Advancements have been made in modelling approaches, evolving from Rosenthal’s basic analytical model progressing into Goldak’s continuum model. Initially considered in a welding context, these two basic models are adaptable and are commonly used for laser heating processes. DIABLO, a continuum thermomechanical model associated with the Lawrence Livermore National Laboratory, is reviewed. The significance of powder bed models and fluid flow in the melt pool, particularly Marangoni convection, will be investigated within the literature. Presently the market offers several commercial software packages for AM, including packages offered by ANSYS, COMSOL and MSC. State-of-the art software packages will be reviewed by comparing their specific claims and investigating those claims where possible.",
keywords = "Additive Manufacturing, Powder Bed Fusion, Thermal Modelling, Simulation",
author = "S McFadden and JP Quinn and Anna Harley",
year = "2018",
month = "7",
day = "20",
language = "English",
note = "The 35th International Manufacturing Conference, IMC35 ; Conference date: 20-06-2018 Through 20-06-2018",
url = "http://www.manufacturingcouncil.ie/about.php",

}

McFadden, S, Quinn, JP & Harley, A 2018, 'A REVIEW OF THERMAL MODELLING FOR METAL ADDITIVE MANUFACTURING PROCESSES: BASIC ANALYTICAL MODELS TO STATE-OF-THE-ART SOFTWARE PACKAGES.' Paper presented at The 35th International Manufacturing Conference, Dublin, Ireland, 20/06/18 - 20/06/18, .

A REVIEW OF THERMAL MODELLING FOR METAL ADDITIVE MANUFACTURING PROCESSES: BASIC ANALYTICAL MODELS TO STATE-OF-THE-ART SOFTWARE PACKAGES. / McFadden, S; Quinn, JP; Harley, Anna.

2018. Paper presented at The 35th International Manufacturing Conference, Dublin, Ireland.

Research output: Contribution to conferencePaper

TY - CONF

T1 - A REVIEW OF THERMAL MODELLING FOR METAL ADDITIVE MANUFACTURING PROCESSES: BASIC ANALYTICAL MODELS TO STATE-OF-THE-ART SOFTWARE PACKAGES.

AU - McFadden, S

AU - Quinn, JP

AU - Harley, Anna

PY - 2018/7/20

Y1 - 2018/7/20

N2 - This contribution will review computer modelling of metal Additive Manufacturing processes that involve a moving point heat source, with attention given to powder bed fusion . Modelling AM processes is important; because it allows AM practitioners to enhance understanding and will help improve the process at the planning stage of the manufacturing process. Full thermal modelling of PBF processes is a significant challenge but it will facilitate improved prediction of levels of porosity and the formation of microstructures. Thermal history of a part is the starting point for a residual stress analysis and therefore imperative. Advancements have been made in modelling approaches, evolving from Rosenthal’s basic analytical model progressing into Goldak’s continuum model. Initially considered in a welding context, these two basic models are adaptable and are commonly used for laser heating processes. DIABLO, a continuum thermomechanical model associated with the Lawrence Livermore National Laboratory, is reviewed. The significance of powder bed models and fluid flow in the melt pool, particularly Marangoni convection, will be investigated within the literature. Presently the market offers several commercial software packages for AM, including packages offered by ANSYS, COMSOL and MSC. State-of-the art software packages will be reviewed by comparing their specific claims and investigating those claims where possible.

AB - This contribution will review computer modelling of metal Additive Manufacturing processes that involve a moving point heat source, with attention given to powder bed fusion . Modelling AM processes is important; because it allows AM practitioners to enhance understanding and will help improve the process at the planning stage of the manufacturing process. Full thermal modelling of PBF processes is a significant challenge but it will facilitate improved prediction of levels of porosity and the formation of microstructures. Thermal history of a part is the starting point for a residual stress analysis and therefore imperative. Advancements have been made in modelling approaches, evolving from Rosenthal’s basic analytical model progressing into Goldak’s continuum model. Initially considered in a welding context, these two basic models are adaptable and are commonly used for laser heating processes. DIABLO, a continuum thermomechanical model associated with the Lawrence Livermore National Laboratory, is reviewed. The significance of powder bed models and fluid flow in the melt pool, particularly Marangoni convection, will be investigated within the literature. Presently the market offers several commercial software packages for AM, including packages offered by ANSYS, COMSOL and MSC. State-of-the art software packages will be reviewed by comparing their specific claims and investigating those claims where possible.

KW - Additive Manufacturing

KW - Powder Bed Fusion

KW - Thermal Modelling

KW - Simulation

M3 - Paper

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