Get 20M+ Full-Text Papers For Less Than $1.50/day. Start a 14-Day Trial for You or Your Team.

Learn More →

Assessment of geometrical defects caused by thermal distortions in laser-beam-melting additive manufacturing: a simulation approach

Assessment of geometrical defects caused by thermal distortions in laser-beam-melting additive... The purpose of this paper is to develop a numerical approach inspired by Geometrical Product Specifications (GPS) standards for the assessment of geometrical defects appearing during Additive Manufacturing (AM) by Laser Beam Melting (LBM).Design/methodology/approachThe study is based on finite element (FE) simulations of thermal distortions, then an assessment of flatness defects (warping induced by the high-residual stresses appearing during the manufacturing) from the deformed surfaces provided by simulation, and finally the correction of the calculated flatness defects from preliminary comparison between simulated and experimental data.FindingsFor an elementary geometrical feature (a wall), it was possible to identify the variation in the flatness defect as a function of the dimensions. For a complex geometry exhibiting a significant flatness defect, it was possible to improve the geometric quality using the numerical tool.Research limitations/implicationsTo the best of the author’s knowledge, this work is the first attempt using a numerical approach inspired by GPS standards to identify variations in thermal distortions caused by LBM, which is an initial step toward optimization. This paper is mainly focused on flatness defect assessment, even though the approach is potentially applicable for all types of geometrical defects (shape, orientation or position defects).Practical implicationsThe study opens prospects for the optimization of complex parts elaborated using LBM, based on the minimization of the geometric defects caused by thermal distortions.Social implicationsThe prospects in terms of shape optimization will extend the potential to benefit from the new possibilities offered by LBM additive manufacturing.Originality/valueUnlike the usual approach, the proposed methodology does not require any artifacts or comparisons with the computer-aided-design (CAD) model for geometrical distortion assessment. The present approach opens up the possibility of performing metrology from FE simulation results, which is particularly promising in the AM field. http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png Rapid Prototyping Journal Emerald Publishing

Assessment of geometrical defects caused by thermal distortions in laser-beam-melting additive manufacturing: a simulation approach

Download PDF
12 pages

Loading next page...
 
/lp/emerald-publishing/assessment-of-geometrical-defects-caused-by-thermal-distortions-in-AL0ZCXD9HN
Publisher
Emerald Publishing
Copyright
© Emerald Publishing Limited
ISSN
1355-2546
DOI
10.1108/rpj-01-2019-0016
Publisher site
See Article on Publisher Site

Abstract

The purpose of this paper is to develop a numerical approach inspired by Geometrical Product Specifications (GPS) standards for the assessment of geometrical defects appearing during Additive Manufacturing (AM) by Laser Beam Melting (LBM).Design/methodology/approachThe study is based on finite element (FE) simulations of thermal distortions, then an assessment of flatness defects (warping induced by the high-residual stresses appearing during the manufacturing) from the deformed surfaces provided by simulation, and finally the correction of the calculated flatness defects from preliminary comparison between simulated and experimental data.FindingsFor an elementary geometrical feature (a wall), it was possible to identify the variation in the flatness defect as a function of the dimensions. For a complex geometry exhibiting a significant flatness defect, it was possible to improve the geometric quality using the numerical tool.Research limitations/implicationsTo the best of the author’s knowledge, this work is the first attempt using a numerical approach inspired by GPS standards to identify variations in thermal distortions caused by LBM, which is an initial step toward optimization. This paper is mainly focused on flatness defect assessment, even though the approach is potentially applicable for all types of geometrical defects (shape, orientation or position defects).Practical implicationsThe study opens prospects for the optimization of complex parts elaborated using LBM, based on the minimization of the geometric defects caused by thermal distortions.Social implicationsThe prospects in terms of shape optimization will extend the potential to benefit from the new possibilities offered by LBM additive manufacturing.Originality/valueUnlike the usual approach, the proposed methodology does not require any artifacts or comparisons with the computer-aided-design (CAD) model for geometrical distortion assessment. The present approach opens up the possibility of performing metrology from FE simulation results, which is particularly promising in the AM field.

Journal

Rapid Prototyping Journal – Emerald Publishing

Published: Aug 21, 2019

Keywords: Additive manufacturing; Process simulation; Laser beam melting; Geometrical specification; Powder bed fusion; Thermal distortions; Straigthness

References

  • The achievable mechanical properties of SLM produced maraging steel 300 components
    Becker, T.H.; Dimitrov, D.
  • Production tolerance of additive manufactured polymeric objects for clinical applications
    Braian, M.; Jimbo, R.; Wennerberg, A.
  • Geometrical variations management for additive manufactured product
    Dantan, J.Y.; Huang, Z.; Goka, E.; Homri, L.; Etienne, A.; Bonnet, N.; Rivette, M.
  • Fatigue characterization of 3D-printed maraging steel by infrared thermography
    Douellou, C.; Balandraud, X.; Duc, E.; Kramer, S.; Jordan, J.; Jin, H.; Carroll, J.; Beese, A.
  • ESI additive manufacturing 2018.0
  • 3D data export for additive Manufacturing-Improving geometric accuracy
    Hällgren, S.; Pejryd, L.; Ekengren, J.
  • Geometrical deviation identification and prediction method for additive manufacturing
    Huang, Z.; Dantan, J.Y.; Etienne, A.; Rivette, M.; Bonnet, N.
  • ISO 1101: geometrical product specifications (GPS) – tolerances of form, orientation, location and run out”, 2017-04-01
  • Additive manufacturing: toward holistic design
    Jared, B.H.; Aguilo, M.A.; Beghini, L.L.; Boyce, B.L.; Clark, B.W.; Cook, A.; Kaehr, B.J.; Robbins, J.
  • A non-retraction path planning approach for extrusion-based additive manufacturing
    Jin, Y.; He, Y.; Fu, G.; Zhang, A.; Du, J.
  • Systematical determination of tolerances for additive manufacturing by measuring linear dimensions
    Lieneke, T.; Adam, G.A.O.; Leuders, S.; Knoop, F.; Josupeit, S.; Delfs, P.; Fuke, N.; Zimmer, D.; Bourell, D.L.
  • Dimensional tolerances for additive manufacturing: experimental investigation for fused deposition modeling
    Lieneke, T.; Denzer, V.; Adam, G.A.O.; Zimmer, D.
  • Tolerance analysis in manufacturing using process capability ratio with measurement uncertainty
    Mahshid, R.; Mansourvar, Z.; Hansen, H.N.
  • Metal additive-manufacturing process and residual stress modeling
    Megahed, M.; Mindt, H.W.; N’Dri, N.; Duan, H.Z.; Desmaison, O.
  • Geometrical product specification and verification in additive manufacturing
    Moroni, G.; Petrò, S.; Polini, W.
  • Fast prediction of thermal distortion in metal powder bed fusion additive manufacturing: part 1, a thermal circuit network model
    Peng, H.; Ghasri-Khouzani, M.; Gong, S.; Attardo, R.; Ostiguy, P.; Gatrell, B.A.; Budzinski, J.; Tomonto, C.; Neidig, J.; Shankar, M.R.; Billo, R.; Go, D.B.; Hoelzle, D.
  • Fast prediction of thermal distortion in metal powder bed fusion additive manufacturing: part 2, a quasi-static thermo-mechanical model
    Peng, H.; Ghasri-Khouzani, M.; Gong, S.; Attardo, R.; Ostiguy, P.; Gatrell, B.A.; Budzinski, J.; Tomonto, C.; Neidig, J.; Shankar, M.R.; Billo, R.; Go, D.B.; Hoelzle, D.
  • A novel methodology of design for additive manufacturing applied to additive laser manufacturing process
    Ponche, R.; Kerbrat, O.; Mognol, P.; Hascoet, J.Y.
  • Fatigue behaviour of selective laser melting steel components
    Santos, L.M.S.; Ferreira, J.A.M.; Jesus, J.S.; Costa, J.M.; Capela, C.
  • Fast deviation simulation for “fused deposition modeling” process
    Shahrain, M.; Didier, T.; Lim, G.K.; Qureshi, A.J.
  • An additive manufacturing oriented design approach to mechanical assemblies
    Sossou, G.; Demoly, F.; Montavon, G.; Gomes, S.
  • Additive Manufacturing – Considerations on geometric accuracy and factors of influence
    Umaras, E.; Tsuzuki, M.S.G.
  • Material jetting additive manufacturing: an experimental study using designed metrological benchmarks
    Yap, Y.L.; Wang, C.; Sing, S.L.; Dikshit, V.; Yeong, W.Y.; Wei, J.
  • Deviation modeling and shape transformation in design for additive manufacturing
    Zhu, Z.; Anwer, N.; Mathieu, L.