Thermo Mechanical Modeling Of Additive Manufacturing

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Author: Michael Gouge
Publisher: Butterworth-Heinemann
ISBN: 0128118210
Size: 44.12 MB
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Thermo Mechanical Modeling Of Additive Manufacturing by Michael Gouge


Original Title: Thermo Mechanical Modeling Of Additive Manufacturing

Thermo-mechanical Modeling of Additive Manufacturing provides the background, methodology and description of modeling techniques to enable the reader to perform their own accurate and reliable simulations of any additive process. Part I provides an in depth introduction to the fundamentals of additive manufacturing modeling, a description of adaptive mesh strategies, a thorough description of thermal losses and a discussion of residual stress and distortion. Part II applies the engineering fundamentals to direct energy deposition processes including laser cladding, LENS builds, large electron beam parts and an exploration of residual stress and deformation mitigation strategies. Part III concerns the thermo-mechanical modeling of powder bed processes with a description of the heat input model, classical thermo-mechanical modeling, and part scale modeling. The book serves as an essential reference for engineers and technicians in both industry and academia, performing both research and full-scale production. Additive manufacturing processes are revolutionizing production throughout industry. These technologies enable the cost-effective manufacture of small lot parts, rapid repair of damaged components and construction of previously impossible-to-produce geometries. However, the large thermal gradients inherent in these processes incur large residual stresses and mechanical distortion, which can push the finished component out of engineering tolerance. Costly trial-and-error methods are commonly used for failure mitigation. Finite element modeling provides a compelling alternative, allowing for the prediction of residual stresses and distortion, and thus a tool to investigate methods of failure mitigation prior to building. Provides understanding of important components in the finite element modeling of additive manufacturing processes necessary to obtain accurate results Offers a deeper understanding of how the thermal gradients inherent in additive manufacturing induce distortion and residual stresses, and how to mitigate these undesirable phenomena Includes a set of strategies for the modeler to improve computational efficiency when simulating various additive manufacturing processes Serves as an essential reference for engineers and technicians in both industry and academia

Thermo Mechanical Model Development And Experimental Validation For Directed Energy Deposition Additive Manufacturing Processes

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Author: Jarred Heigel
Publisher:
ISBN:
Size: 65.51 MB
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Thermo Mechanical Model Development And Experimental Validation For Directed Energy Deposition Additive Manufacturing Processes by Jarred Heigel


Original Title: Thermo Mechanical Model Development And Experimental Validation For Directed Energy Deposition Additive Manufacturing Processes

Additive manufacturing (AM) enables parts to be built through the layer-by-layer addition of molten metal. In directed energy deposition (DED) AM, metal powder or wire is added into a melt pool that follows a pattern to fill in the cross section of the part. When compared to traditional manufacturing processes, AM has manyadvantages such as the ability to make internal features and to repair high-value parts. However, the large thermal gradients generated by AM result in plastic deformation. Thermo-mechanical models must be developed to predict the temperature and distortion produced by this process.Thermo-mechanical models have been developed for AM by several investigators. These models are often validated by measuring the temperatures during the deposition of a small part and the final distortion of the part. Unfortunately this is not a sufficientvalidation method for the non-linear thermo-mechanical model. Although good agreement between the thermal model and the temperatures measured during a small depositions can be achieved, it does not necessarily mean that the model will be accurate for an industrially relevant part that requires 10^2 - 10^4 tracks and hours of processing time. The relatively small deviations between the model and the validation will propagate when modeling large depositions and could produce inaccurate results. The errors in a large part will be increased further if the assumptions made of thethermal boundary conditions are not appropriate for the system.The objective of this work is to develop and experimentally validate thermo-mechanical models for DED. Experiments are performed to characterize the distortion induced by laser cladding. The depositions require many tracks and nearly an hour of processing time, during which the temperature and the deflection are measured in situ so that the response of the plate to each deposition track is understood. Measurements are then made of the convection caused by two different laser deposition heads. Thermo-mechanical models are developed by implementing the measured rate of convective heat transfer and the temperature dependent material properties. The models are validated using in situ measurements of the temperatureand the deflection generated during the process, as well as post-process measurements of the residual stress and the distortedshape. Finally, experiments and models are used to investigate the impact of feedstock selection, either powder or wire, on the DEDprocess.

Laser Based Additive Manufacturing Of Metal Parts

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Author: Linkan Bian
Publisher: CRC Press
ISBN: 1351647482
Size: 47.37 MB
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Laser Based Additive Manufacturing Of Metal Parts by Linkan Bian


Original Title: Laser Based Additive Manufacturing Of Metal Parts

Laser-Based Additive Manufacturing (LBAM) technologies, hailed by some as the "third industrial revolution," can increase product performance, while reducing time-to-market and manufacturing costs. This book is a comprehensive look at new technologies in LBAM of metal parts, covering topics such as mechanical properties, microstructural features, thermal behavior and solidification, process parameters, optimization and control, uncertainty quantification, and more. The book is aimed at addressing the needs of a diverse cross-section of engineers and professionals.

An Adaptive Discrete Element Method For Physical Modeling Of The Selective Laser Sintering Process

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Author: Arash Gobal
Publisher:
ISBN: 9780355151800
Size: 64.45 MB
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An Adaptive Discrete Element Method For Physical Modeling Of The Selective Laser Sintering Process by Arash Gobal


Original Title: An Adaptive Discrete Element Method For Physical Modeling Of The Selective Laser Sintering Process

Additive Manufacturing (AM) has recently risen to the forefront of research and development of manufacturing industries as it provides engineers with unique capabilities that are completely unheard of in subtractive manufacturing systems. Properties such as the fabrication of complex, otherwise not-manufacturable, structures and non-expensive low-volume fabrication have helped additive manufacturing to climb the popularity ladder in such a way that it is sometimes even referred to as "The third industrial revolution". The main distinction between AM and subtractive manufacturing technologies (milling, etc.) is that instead of cutting material from a solid block, AM systems fabricate the end-use products directly in an additive, layer-wise fashion. Selective Laser Sintering (SLS) is categorized as a Powder Bed Fusion (PBF) process. PBF processes are a distinct class of AM systems that use powders as their raw material and use a laser/electron beam to fuse the powders together and fabricate the final product. Powdered metals and ceramics are two of the major raw materials used in PBF processes, resulting in a high demand for industry-scale PBF machines. Therefore, characterization of these processes is a research topic worth exploring. This dissertation presents a comprehensive approach for addressing the ongoing issues in the field of physical modeling of powder bed fusion additive manufacturing processes. In this work, an adaptive discrete element method is proposed for thermo-mechanical simulation of powdered material during the selective laser sintering process. By adding adaptive refinement to the conventional particle level discrete element model, the developed model gets equipped with the capability of improving the simulation speed while maintaining the computational accuracy of the conventional DEM. Empirical models for fusion of powder particle under the influence of the laser beam is also included in the simulation. Moreover, a homogenization technique based on the results of the developed thermo-mechanical method is presented that has the potential of calculating the elastic properties of SLS products. The developed models have been validated, showing that their results follow the expected trends. This dissertation is an effort in creating a much needed physical modeling tool for complete virtual manufacturing and testing of SLS products. Further development of this idea could significantly increase the impact of AM technologies in a wide range of industrial applications.

Minimization Of Welding Distortion And Buckling

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Author: Pan Michaleris
Publisher: Elsevier
ISBN: 0857092901
Size: 34.63 MB
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Minimization Of Welding Distortion And Buckling by Pan Michaleris


Original Title: Minimization Of Welding Distortion And Buckling

Welding is a cost-effective and flexible method of fabricating large structures, but drawbacks such as residual stress, distortion and buckling must be overcome in order to optimize structural performance. Minimization of welding distortion and buckling provides a systematic overview of the methods of minimizing distortion and buckling in welded structures. Following an introductory chapter, part one focuses on understanding welding stress and distortion, with chapters on such topics as computational welding mechanics, modelling the effect of phase transformations on welding stress and distortion and using computationally efficient reduced-solution methods to understand welding distortion. Part two covers different methods of minimizing welding distortion. Chapters discuss methods such as differential heating for minimizing distortion in welded stiffeners, dynamic thermal tensioning, reverse-side heating and ways of minimizing buckling such as weld cooling and hybrid laser arc welding. With its distinguished editor and international team of contributors, Minimization of welding distortion and buckling is an essential reference for all welders and engineers involved in fabrication of metal end-products, as well as those in industry and academia with a research interest in the area. Provides a systematic overview of the methods of minimizing distortion and buckling in welded structures Focuses on understanding welding stress and distortion featuring computational welding mechanics and modelling the effect of phase transformations Explores different methods of minimizing welding distortion discussing differential heating and dynamic thermal tensioning

Additive Manufacturing Of Metals The Technology Materials Design And Production

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Author: Li Yang
Publisher: Springer
ISBN: 3319551280
Size: 78.60 MB
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Additive Manufacturing Of Metals The Technology Materials Design And Production by Li Yang


Original Title: Additive Manufacturing Of Metals The Technology Materials Design And Production

This book offers a unique guide to the three-dimensional (3D) printing of metals. It covers various aspects of additive, subtractive, and joining processes used to form three-dimensional parts with applications ranging from prototyping to production. Examining a variety of manufacturing technologies and their ability to produce both prototypes and functional production-quality parts, the individual chapters address metal components and discuss some of the important research challenges associated with the use of these technologies. As well as exploring the latest technologies currently under development, the book features unique sections on electron beam melting technology, material lifting, and the importance this science has in the engineering context. Presenting unique real-life case studies from industry, this book is also the first to offer the perspective of engineers who work in the field of aerospace and transportation systems, and who design components and manufacturing networks. Written by the leading experts in this field at universities and in industry, it provides a comprehensive textbook for students and an invaluable guide for practitioners

Industrializing Additive Manufacturing Proceedings Of Additive Manufacturing In Products And Applications Ampa2017

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Author: Mirko Meboldt
Publisher: Springer
ISBN: 3319668668
Size: 44.56 MB
Format: PDF
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Industrializing Additive Manufacturing Proceedings Of Additive Manufacturing In Products And Applications Ampa2017 by Mirko Meboldt


Original Title: Industrializing Additive Manufacturing Proceedings Of Additive Manufacturing In Products And Applications Ampa2017

These proceedings exchange ideas and knowledge among engineers, designers and managers on how to support real-world value chains by developing additive manufactured series products. The papers from the conference show a holistic, multidisciplinary view.

Solid Freeform And Additive Fabrication 2000

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Author: Stephen C. Danforth
Publisher: Cambridge University Press
ISBN:
Size: 23.32 MB
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Solid Freeform And Additive Fabrication 2000 by Stephen C. Danforth


Original Title: Solid Freeform And Additive Fabrication 2000

This book, first published in 2000, brings together experts in the field to discuss developments in (solid freeform) SFF and additive methods for fabricating metals, ceramics, polymers, and composites. It focuses on processing-structure-property relationships and relevant materials modeling approaches. Methods ranging from laser chemical vapor deposition (LCVD) to ink-jet based processes are presented. The entire range of materials, i.e., polymeric, metallic and ceramic components for structural, biological, and electronic applications, are also addressed, as are applications of these advanced processing techniques. A joint session with Symposium V, Materials Development for Direct Write Technologies, is included in the proceedings and features materials approaches that are currently being developed for fabricating mesoscopic integrated conformal electronics (MICE). These papers describe materials and methods to fabricate passive electronic devices (such as conductors, insulators and capacitors) on conformal surfaces at temperatures below 400°C. Topics include: direct metal fabrication; tooling and photo processing; direct patterning; composites and ceramics; and ceramics and solution processes.

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