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A scan-wise adaptive remeshing framework for thermal simulation of the selective laser melting process
摘要： Physics-based thermal simulation of laser powder bed fusion can greatly help understanding the process and reducing time and cost associated with experimental approaches. Numerical methods including the finite element method have been widely used to predict parts thermal-structural history during the build process. However, the simulation has scalability issues because both layer thickness and laser spot diameter are too tiny compared to the part-scale. Therefore, it is only feasible to run these simulations with massive computational resources or if the boundary conditions are simplified, which inevitably reduces the prediction accuracy. This paper proposes a tetrahedral element-based scan-wise adaptive remeshing framework for thermal simulation of the selective laser melting (SLM) process. Results show that a significant reduction of the computational time and resources can be achieved due to the reduction of the number of nodes. The proposed framework enables part-scale thermal modeling of the SLM process with detailed thermal history without sacrificing the accuracy. The effectiveness of the proposed framework is demonstrated through a large size cantilever problem.
关键词： Selective laser melting,Melt pool,Adaptive remeshing,Thermal simulation
更新于2025-09-23 15:19:57
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Probing a novel heat source model and adaptive remeshing technique to simulate laser powder bed fusion with experimental validation
摘要： A finite element method based three-dimensional heat transfer model with adaptive remeshing is presented to simulate the building of multiple tracks and layers in laser powder bed fusion of metallic powders with enhanced computational competence. A dimensional analysis is undertaken to define the heat source dimensions as function of laser parameters and properties of alloy powder. The computational model is used to calculate the melt pool cross sections for multiple combinations of laser power and scanning velocities considering multi-track-multi-layer builds of SS316L powder. The computed results are verified extensively with the corresponding experimentally measured ones. The model is utilized further to examine its ability to predict defects such as melt track discontinuity and incomplete fusion between neighboring tracks and layers. Overall, the adaptive remeshing and the proposed heat source expression could significantly enhance the model competence by reducing the computational time and memory while maintaining the accuracy of results in simulating laser powder bed fusion of multiple tracks and layers.
关键词： Selective laser melting (SLM),Pool dimensions,Adaptive remeshing,Laser powder bed fusion (L-PBF),Melt pool defects,SS316L alloy
更新于2025-09-23 15:19:57