Thermo Mechanical Modeling of Additive Manufacturing Book
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Thermo Mechanical Modeling of Additive Manufacturing

  • Author : Michael Gouge
  • Publisher : Butterworth-Heinemann
  • Release Date : 2017-08-03
  • Genre: Technology & Engineering
  • Pages : 294
  • ISBN 10 : 9780128118214

Thermo Mechanical Modeling of Additive Manufacturing Excerpt :

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 ind

Thermo mechanical Model Development and Experimental Validation for Metallic Parts in Additive Manufacturing Book

Thermo mechanical Model Development and Experimental Validation for Metallic Parts in Additive Manufacturing

  • Author : Erik Denlinger
  • Publisher : Unknown
  • Release Date : 2015
  • Genre: Uncategoriezed
  • Pages : null
  • ISBN 10 : OCLC:927776004

Thermo mechanical Model Development and Experimental Validation for Metallic Parts in Additive Manufacturing Excerpt :

The objective of this work is to experimentally validate thermal andmechanical finite element models of metallic parts produced usingadditive manufacturing (AM) processes. AM offers advantages overother manufacturing processes due the fact that it can produce netand near-net shapes directly from a digital drawing file. Parts canbe produced on a layer by layer basis by melting wire or powdermetal using a laser or an electron beam. The material then cools andsolidifies to form a fully dense geometry. Unfortunately the largethermal gradients cause a buildup of residual stress often takingparts out of tolerance or causing failure by cracking ordelamination. To successfully reduce distortion and residual stressin metallic AM parts without expensive and time consuming trial anderror iterations, an experimentally validated physics based model isneeded.In this work finite element (FE) models for the laser directedenergy deposition (LDED), the Electron Beam Directed Manufacture(EBDM) process, and the Laser Powder-Bed Fusion (LPBF) process aredeveloped and validated. In situ distortion and temperaturemeasurements are taken during the LDED processing of both Ti-6Al-4Vand Inconel 625. The in situexperimental results are used in addition to post-process residualstress measurements to validate a thermo-mechanical model for eachalloy. The results show that each material builds distortiondifferently during AM processing, a previously unknown effect thatmust be accounted for in the model. The thermal boundary conditionsin the model are then modified to allow for the modeling of the EBDMprocess. The EBDM model is validated against in situ temperature anddistortion measurements as well as post-process residual stressmeasurements taken on a single bead wide Ti-6Al-4V wall build.Further model validation is provided by comparing the predictedmechanical response of a large EBDM aerospace component consistingof several thousand deposition tracks to post-process distortionmeasurements taken

Thermo mechanical Model Development and Experimental Validation for Directed Energy Deposition Additive Manufacturing Processes Book

Thermo mechanical Model Development and Experimental Validation for Directed Energy Deposition Additive Manufacturing Processes

  • Author : Jarred Heigel
  • Publisher : Unknown
  • Release Date : 2015
  • Genre: Uncategoriezed
  • Pages : null
  • ISBN 10 : OCLC:915618727

Thermo mechanical Model Development and Experimental Validation for Directed Energy Deposition Additive Manufacturing Processes Excerpt :

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 hea

Advances on Mechanics  Design Engineering and Manufacturing III Book

Advances on Mechanics Design Engineering and Manufacturing III

  • Author : Lionel Roucoules
  • Publisher : Springer Nature
  • Release Date : 2021-04-21
  • Genre: Technology & Engineering
  • Pages : 439
  • ISBN 10 : 9783030705664

Advances on Mechanics Design Engineering and Manufacturing III Excerpt :

This open access book gathers contributions presented at the International Joint Conference on Mechanics, Design Engineering and Advanced Manufacturing (JCM 2020), held as a web conference on June 2–4, 2020. It reports on cutting-edge topics in product design and manufacturing, such as industrial methods for integrated product and process design; innovative design; and computer-aided design. Further topics covered include virtual simulation and reverse engineering; additive manufacturing; product manufacturing; engineering methods in medicine and education; representation techniques; and nautical, aeronautics and aerospace design and modeling. The book is organized into four main parts, reflecting the focus and primary themes of the conference. The contributions presented here not only provide researchers, engineers and experts in a range of industrial engineering subfields with extensive information to support their daily work; they are also intended to stimulate new research directions, advanced applications of the methods discussed and future interdisciplinary collaborations.

Thermo mechanical Modeling of Metallic Substrates Around Laser induced Melt Pools Book

Thermo mechanical Modeling of Metallic Substrates Around Laser induced Melt Pools

  • Author : Yi Shu
  • Publisher : Unknown
  • Release Date : 2020
  • Genre: Uncategoriezed
  • Pages : null
  • ISBN 10 : OCLC:1195707521

Thermo mechanical Modeling of Metallic Substrates Around Laser induced Melt Pools Excerpt :

Additive manufacturing (AM) has introduced new possibilities of creating sophisticated designs and structures. Selective Laser Melting (SLM) is an AM technique where structures are fabricated by selectively melting and fusing powder layers. In SLM, melt pools are induced by a laser beam moving on the top surface of a substrate submerged in a powder bed. Mechanical properties of additively manufactured metallic parts are known to be strongly affected by thermal histories, and residual stresses arise due to large temperature gradients. Thermo-mechanical models would help to gain information about both, which is usually hard to obtain. This thesis focuses on examining how well thermal histories and residual stresses in metallic substrates around laser-induced melt pools can be computed by thermo-mechanical models, through experiments on substrates of 17-4PH Stainless Steel (SS) and Ti-6Al-4V. In the first set of experiments, one of two different laser beams moves with constant velocity and power over substrates of 17-4PH SS or Ti-6Al-4V. The substrates are sectioned and etched to expose melt pool traces. In the second set of experiments, single-pass lasers move with constant velocity and power on top surfaces of 17-4PH SS substrates. The time evolution of the deflection of substrates are recorded with a high speed camera. Two types of heat transfer models (accounting for and not accounting for convective heat transfer through fluid flow) reproduced the melt pool traces in the first set of experiments. Predicted thermal histories were critically analyzed. As an extension, how well the model accounting for convective heat transfer reproduced the effect of a substrate edge on the melt pool was examined. Later, the model without convective heat transfer was applied to real-time ultrasonic monitoring of a melt pool in metallic substrates. For the second set of experiments, the model based on heat conduction and elasto-viscoplasticity reproduced the time evolution of deflect

Micromanufacturing of Metallic Materials Book

Micromanufacturing of Metallic Materials

  • Author : Jingwei Zhao
  • Publisher : MDPI
  • Release Date : 2021-01-13
  • Genre: Technology & Engineering
  • Pages : 236
  • ISBN 10 : 9783039435098

Micromanufacturing of Metallic Materials Excerpt :

Product miniaturization is a trend for facilitating product usage, enabling product functions to be implemented in microscale geometries, and aimed at reducing product weight, volume, cost and pollution. Driven by ongoing miniaturization in diverse areas, including medical devices, precision equipment, communication devices, micro-electromechanical systems and microsystems technology, the demands for micro metallic products have been tremendously increased. Such a trend requires the development of advanced technology for the micromanufacturing of metallic materials, with regard to producing high-quality micro metallic products that possess excellent dimensional tolerances, the required mechanical properties and improved surface quality. Micromanufacturing differs from conventional manufacturing technology in terms of materials, processes, tools, and machines and equipment, due to the miniaturization nature of the whole micromanufacturing system, which challenges the rapid development of micromanufacturing technology. Such a background has prompted and encouraged us to publish a scholarly book on the topic of the micromanufacturing of metallic materials, with the purpose of providing readers with a valuable document that can be used in the research and development of micromanufacturing technology. This book will be useful for both theoretical and applied research aimed at micromanufacturing technology, and will serve as an important research tool, providing knowledge to be returned to the community not only as valuable scientific literature, but also as technology, processes and productivities.

A Multiscale Thermomechanical Metal Additive Manufacturing Simulation and the Impact of Geometry on Residual Stress and Distortion Book

A Multiscale Thermomechanical Metal Additive Manufacturing Simulation and the Impact of Geometry on Residual Stress and Distortion

  • Author : Luis Fernando Silva Velasco
  • Publisher : Unknown
  • Release Date : 2020
  • Genre: Additive manufacturing
  • Pages : 86
  • ISBN 10 : OCLC:1262996413

A Multiscale Thermomechanical Metal Additive Manufacturing Simulation and the Impact of Geometry on Residual Stress and Distortion Excerpt :

Metal additive manufacturing is an enabling technology for the rapid prototyping and manufacturing of geometrically complex parts that would otherwise be difficult or impossible to manufacture. However, the manufacturing process can produce undesired residual stresses and distortions. The first part of the work describes the implementation of a multiscale, thermo-mechanical simulation modeling the metal powder bed fusion additive manufacturing process. NASA’s Micromechanics Analysis Code was is to incorporate the microscale effects of an evolving material porosity on the predicted macroscale residual fields. The simulation shows that modeling an evolving material porosity, as the material transitions from a metal powder to a solid, significantly affects the magnitude of the residual stresses and distortions, compared to a constant porosity model. The second part of this work uses the developed simulations to assess the effects of geometrical features. A linear regression shows that there is a correlation between the residual fields and the geometry. This suggests that it may be feasible to predictably influence the residual fields by modifying the geometry. This work is part of a larger work aimed at optimizing the geometry to minimize the residual stresses and distortions.

Smart Materials in Additive Manufacturing  volume 2  4D Printing Mechanics  Modeling  and Advanced Engineering Applications Book

Smart Materials in Additive Manufacturing volume 2 4D Printing Mechanics Modeling and Advanced Engineering Applications

  • Author : Mahdi Bodaghi
  • Publisher : Elsevier
  • Release Date : 2022-06-25
  • Genre: Technology & Engineering
  • Pages : 464
  • ISBN 10 : 9780323954310

Smart Materials in Additive Manufacturing volume 2 4D Printing Mechanics Modeling and Advanced Engineering Applications Excerpt :

4D-Printed Smart Materials and Structures: Smart Materials in Additive Manufacturing, Volume Two provides a thorough introduction to the fundamentals of the mechanics, manufacturing, modeling and applications of 4D printed smart materials and structures. The book covers basic theories, definitions and fabrication details of 4D printing and various smart materials such as shape memory polymers, stimuli-responsive hydrogels, pneumatic soft actuators, dielectric elastomer soft robots, liquid crystal elastomers, shape memory alloys, and magnetic stimulus structures. In addition, it examines the mechanics of these materials and their various applications, covering topics such as variable stiffness, miniature-sized 4D printing, and more. Finally, the book includes a chapter on machine learning in 4D printing, with applications in mechanical, aerospace, civil and structural engineering, among others. Covers the mechanics, manufacturing processes and applications of 4D-printed smart materials and structures Discusses applications in civil, mechanical, aerospace, polymer and biomedical engineering Presents experimental, numerical and analytical studies in a simple and straightforward manner, providing tools that can be immediately implemented and adapted by readers to fit their work

Precision Metal Additive Manufacturing Book

Precision Metal Additive Manufacturing

  • Author : Richard Leach
  • Publisher : CRC Press
  • Release Date : 2020-09-21
  • Genre: Technology & Engineering
  • Pages : 404
  • ISBN 10 : 9780429791284

Precision Metal Additive Manufacturing Excerpt :

Additive manufacturing (AM) is a fast-growing sector with the ability to evoke a revolution in manufacturing due to its almost unlimited design freedom and its capability to produce personalised parts locally and with efficient material use. AM companies, however, still face technological challenges such as limited precision due to shrinkage, built-in stresses and limited process stability and robustness. Moreover, often post-processing is needed due to high roughness and remaining porosity. Qualified, trained personnel are also in short supply. In recent years, there have been dramatic improvements in AM design methods, process control, post-processing, material properties and material range. However, if AM is going to gain a significant market share, it must be developed into a true precision manufacturing method. The production of precision parts relies on three principles: Production is robust (i.e. all sensitive parameters can be controlled). Production is predictable (for example, the shrinkage that occurs is acceptable because it can be predicted and compensated in the design). Parts are measurable (as without metrology, accuracy, repeatability and quality assurance cannot be known). AM of metals is inherently a high-energy process with many sensitive and inter-related process parameters, making it susceptible to thermal distortions, defects and process drift. The complete modelling of these processes is beyond current computational power, and novel methods are needed to practicably predict performance and inform design. In addition, metal AM produces highly textured surfaces and complex surface features that stretch the limits of contemporary metrology. With so many factors to consider, there is a significant shortage of background material on how to inject precision into AM processes. Shortage in such material is an important barrier for a wider uptake of advanced manufacturing technologies, and a comprehensive book is thus needed. This book aims to inform

Industrializing Additive Manufacturing   Proceedings of Additive Manufacturing in Products and Applications   AMPA2017 Book

Industrializing Additive Manufacturing Proceedings of Additive Manufacturing in Products and Applications AMPA2017

  • Author : Mirko Meboldt
  • Publisher : Springer
  • Release Date : 2017-09-05
  • Genre: Technology & Engineering
  • Pages : 362
  • ISBN 10 : 9783319668666

Industrializing Additive Manufacturing Proceedings of Additive Manufacturing in Products and Applications AMPA2017 Excerpt :

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.

3D Printing Book

3D Printing

  • Author : Dragan Cvetković
  • Publisher : BoD – Books on Demand
  • Release Date : 2018-10-10
  • Genre: Technology & Engineering
  • Pages : 196
  • ISBN 10 : 9781789239652

3D Printing Excerpt :

This book, "3D Printing", is divided into two parts: the first part is devoted to the relationship between 3D printing and engineering, and the second part shows the impact of 3D printing on the medical sector in general. There are five sections in the first part (sections are dedicated to stereolithography, new techniques of high-resolution 3D printing, application of 3D printers in architecture and civil engineering, the additive production with the metal components and the management of production by using previously mentioned technology in more complex ways). There are four chapters in the second part with the following topics: education of medical staff through surgical simulations, tissue engineering and potential applications of 3D printing in ophthalmology and orthopedics.

Laser Based Additive Manufacturing Book

Laser Based Additive Manufacturing

  • Author : Narendra B. Dahotre
  • Publisher : John Wiley & Sons
  • Release Date : 2022-08-02
  • Genre: Technology & Engineering
  • Pages : 308
  • ISBN 10 : 9783527828821

Laser Based Additive Manufacturing Excerpt :

Laser-Based Additive Manufacturing Explore laser-based additive manufacturing processes via multi-scale modeling and computer simulation In Laser-Based Additive Manufacturing: Modeling, Simulation, and Experiments, a distinguished team of researchers delivers an incisive framework for understanding materials processing using laser-based additive manufacturing (LAM). The book describes the use of computational modeling and simulation to explore and describe the LAM technique, to improve the compositional, phase, and microstructural evolution of the material, and to enhance the mechanical, chemical, and functional properties of the manufactured components. The accomplished authors combine a comprehensive overview of multi-scale modeling and simulation with experimental and practical observations, offering a systematic review of laser-material interactions in advanced LAM processes. They also describe the real-world applications of LAM, including component processing and surface functionalization. In addition to explorations of residual stresses, three-dimensional defects, and surface physical texture in LAM, readers will also find: A thorough introduction to additive manufacturing (AM), including the advantages of AM over conventional manufacturing and the challenges involved with using the technology A comprehensive exploration of computation materials science, including length- and time-scales in materials modeling and the current state of computational modeling in LAM Practical discussions of laser-material interaction in LAM, including the conversion of light energy to heat, modes of heat dissipation, and the dynamics of the melt-pool In-depth examinations of the microstructural and mechanical aspects of LAM integrated with modeling Perfect for materials scientists, mechanical engineers, and physicists, Laser-Based Additive Manufacturing: Modeling, Simulation, and Experiments is perfect for anyone seeking an insightful treatment of this cutting-edge technology in

Polymer Based Additive Manufacturing Book

Polymer Based Additive Manufacturing

  • Author : Declan M. Devine
  • Publisher : Springer Nature
  • Release Date : 2019-09-16
  • Genre: Medical
  • Pages : 277
  • ISBN 10 : 9783030245320

Polymer Based Additive Manufacturing Excerpt :

This book aims to give readers a basic understanding of commonly used additive manufacturing techniques as well as the tools to fully utilise the strengths of additive manufacturing through the modelling and design phase all the way through to post processing. Guidelines for 3D-printed biomedical implants are also provided. Current biomedical applications of 3D printing are discussed, including indirect applications in the rapid manufacture of prototype tooling and direct applications in the orthopaedics, cardiovascular, drug delivery, ear-nose-throat, and tissue engineering fields. Polymer-Based Additive Manufacturing: Biomedical Applications is an ideal resource for students, researchers, and those working in industry seeking to better understand the medical applications of additive manufacturing.