Abstract— This work addresses the analysis and development of computationally efficient distortion prediction numerical methodologies applicable to powder bed based selective laser melting (SLM) process. Initially, state of the art of simplified distortion modelling methodologies based on finite element (FE) models is introduced. Existing methodologies are described in terms of complexity and applicability to SLM process.
The methodology known as inherent shrinkage, previously developed for multipass welding processes, is applied to predict SLM process induced distortion in Inco 718 testing geometry (cantilever). An assessment about predictive capability of this simplified model based on correlation between numerical results and experimental measurements is performed. Experimental distortions are measured after cutting of base plate connected supports. Initially, the influence of meshing, layer activation and equivalent thermal loads is investigated in terms of prediction capability and computational cost. Subsequently, isotropic and non-isotropic thermal expansion coefficients (α) are considered in the FE-model definition. Results demonstrate that it is feasible to accurately predict the distortion induced by different scanning strategies (chess-board pattern, transversal stripes and longitudinal stripes) in short times. Current developments entail a cost-effective alternative for controlling and reducing distortions in SLM parts.
Keywords— Additive manufacturing, distortion prediction, inherent shrinkage, numerical modeling, powder bed fusion.
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