A finite element modeling strategy is developed to allow for the prediction of distortion accumulation in additive manufacturing (AM) large parts (on the order of meters). A 3D thermoelastoplastic analysis is performed using a hybrid quiet inactive element activation strategy combined with adaptive coarsening. At the beginning for the simulation, before material deposition commences, elements corresponding to deposition material are removed from the analysis, then elements are introduced in the model layer by layer in a quiet state with material properties rendering them irrelevant. As the moving energy source is applied on the part, elements are switched to active by restoring the actual material properties when the energy source is applied on them. A layer by layer coarsening strategy merging elements in lower layers of the build is also implemented such that while elements are added on the top of build, elements are merged below maintaining a low number of degrees of freedom in the model for the entire simulation. The effectiveness of the modeling strategy is demonstrated and experimentally validated on a large electron beam deposited Ti–6Al–4V part consisting of 107 deposition layers. The simulation and experiment show good agreement with a maximum error of 29%.
Skip Nav Destination
Sign In or Register for Account
Article navigation
December 2014
Research-Article
Thermomechanical Modeling of Additive Manufacturing Large Parts
Erik R. Denlinger
,
Erik R. Denlinger
1
Department of Mechanical and
Nuclear Engineering,
e-mail: erd5061@psu.edu
Nuclear Engineering,
The Pennsylvania State University
,University Park, PA 16802
e-mail: erd5061@psu.edu
1Corresponding author.
Search for other works by this author on:
Jeff Irwin
,
Jeff Irwin
Department of Mechanical and
Nuclear Engineering,
e-mail: jei5028@psu.edu
Nuclear Engineering,
The Pennsylvania State University
,University Park, PA 16802
e-mail: jei5028@psu.edu
Search for other works by this author on:
Pan Michaleris
Pan Michaleris
Associate Professor
Department of Mechanical and
Nuclear Engineering,
Department of Mechanical and
Nuclear Engineering,
The Pennsylvania State University
,University Park, PA 16802
Search for other works by this author on:
Erik R. Denlinger
Department of Mechanical and
Nuclear Engineering,
e-mail: erd5061@psu.edu
Nuclear Engineering,
The Pennsylvania State University
,University Park, PA 16802
e-mail: erd5061@psu.edu
Jeff Irwin
Department of Mechanical and
Nuclear Engineering,
e-mail: jei5028@psu.edu
Nuclear Engineering,
The Pennsylvania State University
,University Park, PA 16802
e-mail: jei5028@psu.edu
Pan Michaleris
Associate Professor
Department of Mechanical and
Nuclear Engineering,
Department of Mechanical and
Nuclear Engineering,
The Pennsylvania State University
,University Park, PA 16802
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received April 14, 2014; final manuscript received September 19, 2014; published online October 24, 2014. Assoc. Editor: David L. Bourell.
1Corresponding author.
J. Manuf. Sci. Eng. Dec 2014, 136(6): 061007 (8 pages)
Published Online: October 24, 2014
Article history
Received:
April 14, 2014
Revision Received:
September 19, 2014
Citation
Denlinger, E. R., Irwin, J., and Michaleris, P. (October 24, 2014). "Thermomechanical Modeling of Additive Manufacturing Large Parts." ASME. J. Manuf. Sci. Eng. December 2014; 136(6): 061007. https://doi.org/10.1115/1.4028669
Download citation file:
Sign In
Get Email Alerts
Cited By
Friction Surfacing Deposition by Consumable Tools
J. Manuf. Sci. Eng
Flank-Milling of Integral Blade Rotors Made in Ti6Al4V Using Cryo CO2 and Minimum Quantity Lubrication
J. Manuf. Sci. Eng (September 2021)
Related Articles
Understanding Process Parameter Effects of RepRap Open-Source Three-Dimensional Printers Through a Design of Experiments Approach
J. Manuf. Sci. Eng (February,2015)
Image-Based Slicing and Tool Path Planning for Hybrid Stereolithography Additive Manufacturing
J. Manuf. Sci. Eng (July,2017)
Correlation Between Microstructure and Mechanical Properties in an Inconel 718 Deposit Produced Via Electron Beam Freeform Fabrication
J. Manuf. Sci. Eng (December,2014)
On Process Temperature in Powder-Bed Electron Beam Additive Manufacturing: Process Parameter Effects
J. Manuf. Sci. Eng (December,2014)
Related Proceedings Papers
Related Chapters
Microstructure Evolution and Physics-Based Modeling
Ultrasonic Welding of Lithium-Ion Batteries
Ontology-Based Knowledge Construction for Rapid Prototyping Domain
International Conference on Mechanical and Electrical Technology, 3rd, (ICMET-China 2011), Volumes 1–3
Coupled Thermo-Mechanical Simulation
Ultrasonic Welding of Lithium-Ion Batteries