Numerical modeling of residual stresses in additive manufacturing products using the theory of repeatedly superimposed finite strains

Abstract

An approach to the residual stress analysis of parts made by powder bed additive manufacturing is proposed. The approach is based on the theory of repeatedly superimposed finite strains. The problem statement is formulated within the framework of nonlinear thermoelasticity. The method of problem solving is developed on the base of finite and spectral element methods. The numerical modeling of a full-sized experiment is performed. In this experiment, the additive manufactured part is notched in order to estimate residual stresses in it. The obtained numerical results are in good agreement with the experimental results. It is concluded from the results that the developed approach is correct and the nonlinear effects are substantial.