Improving the printing process stability and the geometrical accuracy of the parts manufactured by the additive techniques

Abstract

Abstract Current research is devoted to the computer-aided engineering application for direct modeling of the additive manufacturing process and detailed analysis of the resulting shape of the formed part. The utilized approach is based on the idea that it is possible and efficient to perform a numerical simulation of the process of a layer-by-layer building of the analyzed part, considering all the required mechanical and thermal effects. The results of such simulation should allow obtaining the detailed information about the deformed shape of the printed part before running the printing process itself. Such approach allows avoiding the unsuccessful printing attempts, improve the integral stability of the production process and reduce its cost. The paper presents the methodology of preparing a “digital twin” of the additive manufacturing process performed with AlSi10Mg alloy using one of metal machines and running a simulation of the manufacturing process for a representative structural component. The study has shown that implementation of modeling of the manufacturing process before the printing process leads to significant shape improvements of the parts printed, especially in case of performing additional optimization of the support structures. The research outcomes can be well applied for improving the production processes in the companies working with additive manufacturing in order to increase the stability of the processes and accuracy of the printed parts.