The complexity of local and dynamic thermal transformations in additive manufacturing (AM) processes makes it difficult to track in situ thermomechanical changes at different length scales within a part using experimental process monitoring equipment. In addition, in situ process monitoring is limited to providing information only at the exposed surface of a layer being built. As a result, an understanding of the bulk microstructural transformations and the resulting behavior of a part requires rigorous postprocess microscopy and mechanical testing. In order to circumvent the limited feedback obtained from in situ experiments and to better understand material response, a novel 3D dislocation density based thermomechanical finite element framework has been developed. This framework solves for the in situ response much faster than currently used state-of-the-art modeling software since it has been specifically designed for AM platforms. This modeling infrastructure can predict the anisotropic performance of AM-produced components before they are built, can serve as a method to enable in situ closed-loop process control and as a method to predict residual stress and distortion in parts and thus enable support structure optimization. This manuscript provides an overview of these software modules which together form a robust and reliable AM software suite to address future needs for machine development, material development, and geometric optimization.
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December 2014
Research-Article
An Integrated Approach to Additive Manufacturing Simulations Using Physics Based, Coupled Multiscale Process Modeling
Deepankar Pal,
Deepankar Pal
1
Assistant Professor
Department of Mechanical Engineering,
J.B. Speed School of Engineering,
e-mail: d0pal001@louisville.edu
Department of Mechanical Engineering,
J.B. Speed School of Engineering,
University of Louisville
,Louisville, KY 40292
e-mail: d0pal001@louisville.edu
1Corresponding author.
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Nachiket Patil,
Nachiket Patil
Senior Research Engineer
e-mail: nachiket.patil@3dsim.com
3DSIM, LLC
,201 E. Jefferson Street
,Louisville, KY 40202
e-mail: nachiket.patil@3dsim.com
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Kai Zeng,
Kai Zeng
Department of Industrial Engineering,
J.B. Speed School of Engineering,
e-mail: k0zeng01@louisville.edu
J.B. Speed School of Engineering,
University of Louisville
,Louisville, KY 40292
e-mail: k0zeng01@louisville.edu
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Brent Stucker
Brent Stucker
Clark Chair Professor
J. B. Speed School of Engineering,
e-mail: brent.stucker@louisville.edu
J. B. Speed School of Engineering,
University of Louisville
,Louisville, KY 40292
e-mail: brent.stucker@louisville.edu
Search for other works by this author on:
Deepankar Pal
Assistant Professor
Department of Mechanical Engineering,
J.B. Speed School of Engineering,
e-mail: d0pal001@louisville.edu
Department of Mechanical Engineering,
J.B. Speed School of Engineering,
University of Louisville
,Louisville, KY 40292
e-mail: d0pal001@louisville.edu
Nachiket Patil
Senior Research Engineer
e-mail: nachiket.patil@3dsim.com
3DSIM, LLC
,201 E. Jefferson Street
,Louisville, KY 40202
e-mail: nachiket.patil@3dsim.com
Kai Zeng
Department of Industrial Engineering,
J.B. Speed School of Engineering,
e-mail: k0zeng01@louisville.edu
J.B. Speed School of Engineering,
University of Louisville
,Louisville, KY 40292
e-mail: k0zeng01@louisville.edu
Brent Stucker
Clark Chair Professor
J. B. Speed School of Engineering,
e-mail: brent.stucker@louisville.edu
J. B. Speed School of Engineering,
University of Louisville
,Louisville, KY 40292
e-mail: brent.stucker@louisville.edu
1Corresponding author.
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received April 21, 2014; final manuscript received September 12, 2014; published online October 24, 2014. Assoc. Editor: Joseph Beaman.
J. Manuf. Sci. Eng. Dec 2014, 136(6): 061022 (16 pages)
Published Online: October 24, 2014
Article history
Received:
April 21, 2014
Revision Received:
September 12, 2014
Citation
Pal, D., Patil, N., Zeng, K., and Stucker, B. (October 24, 2014). "An Integrated Approach to Additive Manufacturing Simulations Using Physics Based, Coupled Multiscale Process Modeling." ASME. J. Manuf. Sci. Eng. December 2014; 136(6): 061022. https://doi.org/10.1115/1.4028580
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