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Discrete element modeling of powder layer generation in additive manufacturing
Using a existing Discrete element method implementation, the process of recoating in laser powder bed fusion is to be simulated and compared to experimental results.
Keywords: Additive manufacturing (AM)
Laser powder bed fusion (LPBF)
Recoating
Discrete element method (DEM)
Granular mechanics
Experimental validation
The goal of the joint cooperation between am|z and Inspire AG us to use numerical simulation to find new insights into the process understanding as well as opportunities for improvements that can be realized, facilitating the transfer of AM technologies from rapid prototyping to industrial productions. In LPBF the powder bed morphology plays central role in melt pool formation and laser absorption behaviour. Use of accurate and realistic powder layer properties including surface packing density and laser material interaction are therefore crucial in high-fidelity modelling of LPBF processes and require simulation of the recoating step. At am|z a discrete element method for simulating granular mechanics has been developed, which is predestined to simulate the recoating process. Experimental validation plays a significant role in this thesis
The goal of the joint cooperation between am|z and Inspire AG us to use numerical simulation to find new insights into the process understanding as well as opportunities for improvements that can be realized, facilitating the transfer of AM technologies from rapid prototyping to industrial productions. In LPBF the powder bed morphology plays central role in melt pool formation and laser absorption behaviour. Use of accurate and realistic powder layer properties including surface packing density and laser material interaction are therefore crucial in high-fidelity modelling of LPBF processes and require simulation of the recoating step. At am|z a discrete element method for simulating granular mechanics has been developed, which is predestined to simulate the recoating process. Experimental validation plays a significant role in this thesis
- Setting up a realistic recoating process
- Implementation of non-spherical DEM-particles
- Implementation of powder deformation/compression
- Testing and optimization
- Validation using experimental results and data from literature.
- Setting up a realistic recoating process - Implementation of non-spherical DEM-particles - Implementation of powder deformation/compression - Testing and optimization - Validation using experimental results and data from literature.