The process of selective laser sintering (SLS) involves selective heating and fusion of powdered material using a moving laser beam. Because of its complicated manufacturing process, physical modeling of the transformation from powder to final product in the SLS process is currently a challenge. Existing simulations of transient temperatures during this process are performed either using finite-element (FE) or discrete-element (DE) methods which are either inaccurate in representing the heat-affected zone (HAZ) or computationally expensive to be practical in large-scale industrial applications. In this work, a new computational model for physical modeling of the transient temperature of the powder bed during the SLS process is developed that combines the FE and the DE methods and accounts for the dynamic changes of particle contact areas in the HAZ. The results show significant improvements in computational efficiency over traditional DE simulations while maintaining the same level of accuracy.
Issue Section:
Research Papers
References
1.
Gibson
, I.
, Rosen
, D. W.
, and Stucker
, B.
, 2010
, Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing
, Springer
, Berlin
.2.
Attar
, E.
, 2011
, “Simulation of Selective Electron Beam Melting Processes
,” D. Ing, dissertation, University of Erlangen-Nuremberg, Erlangen, Germany.3.
Kruth
, J.-P.
, Mercelis
, P.
, Van Vaerenbergh
, J.
, Froyen
, L.
, and Rombouts
, M.
, 2005
, “Binding Mechanisms in Selective Laser Sintering and Selective Laser Melting
,” Rapid Prototyping J.
, 11
(1
), pp. 26
–36
.4.
Kruth
, J.-P.
, Levy
, G.
, Klocke
, F.
, and Childs
, T. H. C.
, 2007
, “Consolidation Phenomena in Laser and Powder-Bed Based Layered Manufacturing
,” Procedia CIRP
, 56
(2
), pp. 730
–759
.5.
Chryssolouris
, G.
, 2006
, Manufacturing Systems: Theory and Practice
, 2nd, ed., Springer
, Berlin
, pp. 101
–103
.6.
Duley
, W. W.
, 1983
, Laser Processing and Analysis of Materials
, Plenum Press
, New York
.7.
Matsumoto
, M.
, Shiomi
, M.
, Osakada
, K.
, and Abe
, F.
, 2002
, “Finite Element Analysis of Single Layer Forming on Metallic Powder Bed in Rapid Prototyping by Selective Laser Processing
,” Int. J. Mach. Tools Manuf.
, 42
(1
), pp. 61
–67
.8.
Nelson
, J. C.
, Xue
, S.
, Barlow
, J. W.
, Beaman
, J. J.
, Marcus
, H. L.
, and Bourell
, D. L.
, 1993
, “Model of the Selective Laser Sintering of Bisphenol-A Polycarbonate
,” Ind. Eng. Chem. Res.
, 32
(10
), pp. 2305
–2317
.9.
Bugeda
, G.
, Cervera
, M.
, and Lombera
, G.
, 1999
, “Numerical Prediction of Temperature and Density Distributions in Selective Laser Sintering Processes
,” Rapid Prototyping J.
, 5
(1
), pp. 21
–26
.10.
Kolossov
, S.
, Boillat
, E.
, Glardon
, R.
, Fischer
, P.
, and Locher
, M.
, 2004
, “3D FE Simulation for Temperature Evolution in the Selective Laser Sintering Process
,” Int. J. Mach. Tools Manuf.
, 44
(2–3), pp. 117
–123
.11.
Patil
, R. B.
, and Yadava
, V.
, 2007
, “Finite Element Analysis of Temperature Distribution in Single Metallic Powder Layer During Metal Laser Sintering
,” Int. J. Mach. Tools Manuf.
, 47
(7–8), pp. 1069
–1080
.12.
Xing
, J.
, Sun
, W.
, and Rana
, R. S.
, 2013
, “3D Modeling and Testing of Transient Temperature in Selective Laser Sintering (SLS) Process
,” Optik
, 124
(4
), pp. 301
–304
.13.
Parhami
, F.
, and McMeeking
, R. M.
, 1998
, “A Network Model for Initial Stage Sintering
,” Mech. Mater.
, 27
(2
), pp. 111
–124
.14.
Zhou
, J.
, Zhang
, Y.
, and Chen
, J. K.
, 2009
, “Numerical Simulation of Random Packing of Spherical Particles for Powder-Based Additive Manufacturing
,” ASME J. Manuf. Sci. Eng.
, 131
(3
), p. 031004
.15.
He
, D.
, Ekere
, N. N.
, and Cai
, L.
, 1999
, “Computer Simulation of Random Packing of Unequal Particles
,” Phys. Rev. E
, 60
(6
), pp. 7098
–7104
.16.
Zeng
, K.
, Pal
, D.
, Patil
, N.
, and Stucker
, B.
, 2013
, “A New Dynamic Mesh Method Applied to the Simulation of Selective Laser Melting
,” 24th International SFF Symposium—An Additive Manufacturing Conference
, SFF 2013, pp. 549
–559
.17.
Pal
, D.
, Patil
, N.
, Zeng
, K.
, and Stucker
, B.
, 2014
, “An Integrated Approach to Additive Manufacturing Simulations Using Physics Based, Coupled Multiscale Process Modeling
,” ASME J. Manuf. Sci. Eng.
, 136
(6
), p. 061022
.18.
Abyzov
, A. M.
, Goryunov
, A. V.
, and Shakhov
, F. M.
, 2013
, “Effective Thermal Conductivity of Disperse Materials. I. Compliance of Common Models With Experimental Data
,” Int. J. Heat Mass Transfer
, 67
, pp. 752
–767
.19.
Ganeriwala
, R.
, and Zohdi
, T. I.
, 2014
, “Multiphysics Modeling and Simulation of Selective Laser Sintering Manufacturing Process
,” Procedia CIRP
, 14
, pp. 299
–304
.20.
Zohdi
, T. I.
, 2013
, “Rapid Simulation of Laser Processing of Discrete Particulate Materials
,” Arch. Comput. Methods Eng.
, 20
(4
), pp. 309
–325
.21.
Kovaleva
, I.
, Kovalev
, O.
, and Smurov
, I.
, 2014
, “Model of Heat and Mass Transfer in Random Packing Layer of Powder Particles in Selective Laser Melting
,” Phys. Procedia
, 56
, pp. 400
–410
.22.
Haddad
, H.
, Guessasma
, M.
, and Fortin
, J.
, 2014
, “Heat Transfer by Conduction Using DEM-FEM Coupling Method
,” Comput. Mater. Sci.
, 81
, pp. 339
–347
.23.
Zhou
, J.
, Zhang
, Y.
, and Chen
, J. K.
, 2009
, “Numerical Simulation of Laser Irradiation to a Randomly Packed Bimodal Powder Bed
,” Int. J. Heat Mass Transfer
, 52
(13–14
), pp. 3137
–3146
.24.
Saleh
, B. E.
, and Teich
, M. C.
, 1991
, Fundamentals of Photonics
, Wiley
, New York
.25.
Sha
, W. C.
, and Ganic
, E. N.
, 1981
, “Transient Heat Conduction at low Biot Numbers: A Supplement to Heisler's Charts
,” Lett. Heat Mass Transfer
, 8
(5
), pp. 379
–395
.26.
Liang
, Y.
, and Li
, X.
, 2014
, “A New Model for Heat Transfer Through the Contact Network of Randomly Packed Granular Material
,” Appl. Therm. Eng.
, 73
(1
), pp. 982
–990
.27.
Cundall
, P. A.
, and Strack
, O. D. L.
, 1979
, “A Discrete Numerical Model for Granular Assemblies
,” Geotechnique
, 29
(1
), pp. 47
–65
.28.
Coble
, R. L.
, 1958
, “Initial Sintering of Alumina and Hematite
,” J. Am. Ceram. Soc.
, 41
(2
), pp. 55
–62
.29.
Martin
, C. L.
, Schneider
, L. C. R.
, Olmos
, L.
, and Bouvard
, D.
, 2006
, “Discrete Element Modeling of Metallic Powder Sintering
,” Scr. Mater.
, 55
(5
), pp. 425
–428
.30.
Hou
, T. Y.
, and Wu
, X.-H.
, 1997
, “A Multiscale Finite Element Method for Elliptic Problems in Composite Materials and Porous Media
,” J. Comput. Phys.
, 134
(1
), pp. 169
–189
.31.
Zhang
, H. W.
, Zhou
, Q.
, and Zheng
, Y. G.
, 2011
, “A Multi-Scale Method for Thermal Conduction Simulation in Granular Materials
,” Comput. Mater. Sci.
, 50
(10
), pp. 2750
–2758
.32.
Bathe
, K. J.
, 1996
, Finite Element Procedures
, Prentice-Hall
, Upper Saddle River, NJ
.Copyright © 2017 by ASME
You do not currently have access to this content.
