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Mechanical simulation for ultra-short pulse Selective Laser Melting of ceramics
The project will start with a literature research about the coupling of fluid dynamics with mechanical simulations. The idea is to use the temperature field from the fluid dynamic simulation in order to develop a mechanical FEM simulation, which is capable to predict the generation of cracks.
Keywords: FEM simulation, additive manufacturing, 3d printing, ceramics, aerospace, biomedical industry
**Introduction**
Additive manufacturing is a fast growing field: it started with processing of plastic materials in the 80s and it was extended to metals in the late 90s. Ceramics, such as alumina and zirconia, are the next challenge for engineers and researchers and this is the reason why a joint project between ETH Zürich, EMPA and PSI started recently. There are multiple applications for which the introduction of additive manufacturing of ceramics may be disruptive, including medical, dental and aerospace industry. This work is aimed at developing a computer simulation that will deepen the understanding of laser melting of ceramics. The focus will be on the estimation of the state of stress in the part.
**Content**
The project is a continuation of two previous theses it will start with a literature research about the coupling of fluid dynamics with mechanical simulations. The idea is to use the temperature field from the fluid dynamic simulation in order to develop a mechanical FEM simulation. The final aim is to evaluate the state of stress in the material due to the thermal gradient induced by the rapid local heat-ing and cooling, in order to predict the formation of cracks. Depending on time issues, experiments may be conducted in order to quantify the amount of cracks in the SLM produced samples and link it to the simulation.
**Tasks**
- Literature review and comparative analysis of different techniques for mechanical simulations
- Developing/Adapting a simulation for SLM of ceramics
- Evaluating the conditions for avoding cracks
- Depending on time issues, analysis of cracks in real SLM-built samples
**Requirements**
- Motivated and proactive working attitude
- Interest/knowledge in simulation
- Analytical thinking
**Outlook**
Workload: 30% Literature review, 50% Implementation, 20% Documentation
Location: ETH Technopark / flexible
Start date: negotiable
**Introduction** Additive manufacturing is a fast growing field: it started with processing of plastic materials in the 80s and it was extended to metals in the late 90s. Ceramics, such as alumina and zirconia, are the next challenge for engineers and researchers and this is the reason why a joint project between ETH Zürich, EMPA and PSI started recently. There are multiple applications for which the introduction of additive manufacturing of ceramics may be disruptive, including medical, dental and aerospace industry. This work is aimed at developing a computer simulation that will deepen the understanding of laser melting of ceramics. The focus will be on the estimation of the state of stress in the part.
**Content** The project is a continuation of two previous theses it will start with a literature research about the coupling of fluid dynamics with mechanical simulations. The idea is to use the temperature field from the fluid dynamic simulation in order to develop a mechanical FEM simulation. The final aim is to evaluate the state of stress in the material due to the thermal gradient induced by the rapid local heat-ing and cooling, in order to predict the formation of cracks. Depending on time issues, experiments may be conducted in order to quantify the amount of cracks in the SLM produced samples and link it to the simulation.
**Tasks** - Literature review and comparative analysis of different techniques for mechanical simulations - Developing/Adapting a simulation for SLM of ceramics - Evaluating the conditions for avoding cracks - Depending on time issues, analysis of cracks in real SLM-built samples
**Requirements** - Motivated and proactive working attitude - Interest/knowledge in simulation - Analytical thinking
**Outlook** Workload: 30% Literature review, 50% Implementation, 20% Documentation Location: ETH Technopark / flexible Start date: negotiable