3-Dimensional Heat Transfer Modeling for Laser Powder Bed Fusion Additive Manufacturing Using Parallel Computing and Adaptive Mesh

49 Pages Posted: 12 May 2022

See all articles by Zhi-Dong Zhang

Zhi-Dong Zhang

University of Waterloo

Shahriar Imani Shahabad

University of Waterloo

Osezua Ibhadode

University of Waterloo

Chinedu Francis Dibia

University of Waterloo

Ali Bonakdar

affiliation not provided to SSRN

Ehsan Toyserkani

University of Waterloo

Abstract

In this article, an innovative 3-dimensional (3D) heat-transfer finite element parallel-computing model with adaptive mesh capability, named LPBFSim, for Laser Powder Bed Fusion (LPBF) additive manufacturing is introduced for high precision prediction of melt pool dimensions and part-level process simulations. Numerical modeling can significantly reduce the expense of the sole deployment of trial-and-error experiments for achieving optimal process parameters. The previously developed single-track model [1] is highly accurate to predict melt pool dimensions for different combinations of process parameters. However, without using parallel computing and an adaptive mesh, it is very challenging to scale it up to a multi-track model or even a part-level model due to the high computational cost. The proposed model is parallelized to be able to run on a cluster and aimed to solve this difficulty while keeping all the accuracy from the previous version. Single-track, multi-track, and part-level models have been implemented to demonstrate its efficiency and accuracy.

Keywords: Additive manufacturing, Laser powder bed fusion, Heat transfer modeling, Volumetric heat sources, Parallel computing, Adaptive mesh

Suggested Citation

Zhang, Zhi-Dong and Shahabad, Shahriar Imani and Ibhadode, Osezua and Dibia, Chinedu Francis and Bonakdar, Ali and Toyserkani, Ehsan, 3-Dimensional Heat Transfer Modeling for Laser Powder Bed Fusion Additive Manufacturing Using Parallel Computing and Adaptive Mesh. Available at SSRN: https://ssrn.com/abstract=4108005 or http://dx.doi.org/10.2139/ssrn.4108005

Zhi-Dong Zhang (Contact Author)

University of Waterloo ( email )

Waterloo, N2L 3G1
Canada

Shahriar Imani Shahabad

University of Waterloo ( email )

Waterloo, N2L 3G1
Canada

Osezua Ibhadode

University of Waterloo ( email )

Waterloo, N2L 3G1
Canada

Chinedu Francis Dibia

University of Waterloo ( email )

Waterloo, N2L 3G1
Canada

Ali Bonakdar

affiliation not provided to SSRN ( email )

No Address Available

Ehsan Toyserkani

University of Waterloo ( email )

Waterloo, N2L 3G1
Canada

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