Research Papers

Numerical Modeling of Metal-Based Additive Manufacturing Using Level Set Methods

[+] Author and Article Information
Qian Ye

Department of Mechanical Engineering,
State University of New York at Stony Brook,
Stony Brook, NY 11790
e-mail: qian.ye@stonybrook.edu

Shikui Chen

Department of Mechanical Engineering,
State University of New York at Stony Brook,
Stony Brook, NY 11790
e-mail: shikui.chen@stonybrook.edu

1Corresponding author.

Manuscript received November 30, 2016; final manuscript received February 9, 2017; published online April 18, 2017. Assoc. Editor: Zhijian J. Pei.

J. Manuf. Sci. Eng 139(7), 071019 (Apr 18, 2017) (8 pages) Paper No: MANU-16-1621; doi: 10.1115/1.4036290 History: Received November 30, 2016; Revised February 09, 2017

The advance in computational science and engineering allows people to simulate the additive manufacturing (AM) process at high fidelity, which has turned out to be a valid way to model, predict, and even design the AM processes. In this paper, we propose a new method to simulate the melting process of metal powder-based AM. The governing physics is described using partial differential equations for heat transfer and Laminar flow. Level set methods are applied to track the free surface motion of the molten metal flow. Some fundamental issues in the metal-based AM process, including free surface evolution, phase transitions, and velocity field calculation, are explored, which help us gain insight into the metal-based AM process. The convergence problem is also examined to improve the efficiency in solving this multiphysics problem.

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Fig. 1

Simulation of selective electron beam melting processes [4]

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Fig. 2

Power intensity distribution of laser beam

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Fig. 6

Evolution of the melt pool geometry, temperature contours, velocity fields, and liquid friction

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Fig. 7

Convergence plots of the full coupled solver and the segregated solver

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Fig. 3

Simulating results of melting and spreading of a single particle

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Fig. 4

Heat capacity of latent heat at t = 0.5 ms

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Fig. 5

Temperature contours and interface changes at different times: (a) t = 0.10 ms and (b) t = 1.1 ms




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