Eventos Anais de eventos
COBEM 2023
27th International Congress of Mechanical Engineering
Numerical Simulation of the Additive Manufacturing Process by Laser Powder Bed Fusion
Submission Author:
Guilherme Moura , RJ
Co-Authors:
Guilherme Moura, Diego Busson de Moraes, Gabriel Rodrigues, Carolina Palma Naveira Cotta
Presenter: Guilherme Moura
doi://10.26678/ABCM.COBEM2023.COB2023-1760
Abstract
The Laser Powder Bed Fusion (L-PBF) process is a promising additive manufacturing technique for the production of complex and customized metallic parts. This process involves the progressive deposition of thin layers of metal powder, which are selectively melted using a laser beam, layer by layer, until the final shape of the part is obtained. However, the quality and reliability of the printed parts are significantly influenced by the process parameters, such as laser power, scan speed, and hatch spacing. A poor selection of these may lead to the formation of defects, such as cracks, porosity and warping. Therefore, in this study, we aim to investigate the impact of these process parameters on the quality of the printed part using numerical simulations and experiments. The objective of this study is to both improve the understanding of the physics of the process and to develop a reliable numerical model that can predict the quality of printed parts for different combinations of process parameters. To achieve these objectives, we developed a three-dimensional numerical model based on the finite volume method to simulate the L-PBF process. The model considers the thermal diffusion in the powder bed, laser-powder interaction, and phase transformation during the melting, evaporation and solidification of the powder particles. The numerical model was calibrated and validated by printing traces with different laser parameters on a powder of the commercial alloy Remanium Star. This allow is of significant interest, specially in the dentistry industry, but still lacks sufficient studies aiming to improve its printability. Our results show that the process parameters have a big influence on the melt pool dimensions, which in turn dictates the quality and allowable build rate of the process. So, by being able to estimate these dimensions, we could build a map of desirable combinations in order to avoid defects while allowing for the optimization of printing resolution and productivity. In conclusion, this study improves the understanding of the impact of process parameters on the quality of the printed L-PBF parts and presents a numerical model that can be used as a powerful tool to optimize the process parameters while preventing defect formations. The results of this study have significant implications for the industrial application of L-PBF and the development of advanced materials for additive manufacturing.
Keywords
Laser powder bed fusion, Numerical simulation, Process optimization, Additive manufacturing
