A computationally efficient universal platform for thermal numerical modeling of laser-based additive manufacturing

Abstract

A macroscopic thermal finite element analysis modeling platform for laser-based additive manufacturing is presented and validated. Its key characteristics include highly automated creation of simulation scenarios and increased computational efficiency. An investigation is carried out proving thermal shells a viable alternative to traditional solid elements, for building smaller and faster models. Full parameterization allows for rapid creation of specific modeling instances/scenarios. The use of shell elements, combined with model reduction techniques and advanced solver technology, result in very significantly reduced simulation times, compared to conventional modeling methods. Validation of the presented platform is carried out by comparison to results from other numerical models as well as experiments identified in the literature. Very good agreement for a wide range of materials and process parameters attest to its accuracy and universal application. This platform is the necessary basis for an Integrated Multiscale Modeling framework for systematically studying thermal patterns thereby ultimately increasing the scope of simulation to complete layers and whole parts.