Study on Development of a Deformation Prediction System for 3D Printed Parts in Additive Manufacturing

SLM is a promising additive manufacturing (AM) process that has the ability to build practically any three-dimensional (3D) metallic item with complex structures. The thermal behaviour of metal powder during the SLM process is critical for sustaining product quality during 3D printing. Furthermore, a high-temperature gradient arises in the heat-affected zone as a result of the high heating and cooling rates used in the selective laser melting (SLM) process, resulting in large residual stresses in the manufactured parts. The goal of this research is to create a deformation prediction system based on temperature distribution in 3D printed objects. A thermo-mechanical coupling model was created for this purpose, and it was used to investigate thermal behaviour, residual stress, and deformation during the SLM process of Ti6Al4V alloy. During the SLM manufacturing utilising Ti6Al4V powder, a TELOPS FAST-IR (M350) thermal imager was used to determine the temperature profile of the melting pool and powder bed along the scanning direction. The numerically calculated findings were compared to the temperature distribution determined empirically. The comparison revealed that the generated thermal model’s calculated peak temperature for a single track was in good agreement with the experiment data. A reliable prediction approach for examining the impacts of process parameters such as laser power and scanning speed on temperature distribution, residual stress, and deformation was developed through simulation. The data revealed that, due to a heat accumulation effect, residual stress on fabricated parts gradually rose throughout the SLM process.

Author(S) Details

Hong Seok Park
School of Mechanical and Automotive Engineering, University of Ulsan, South Korea.

Saurabh Kumar
School of Mechanical and Automotive Engineering, University of Ulsan, South Korea.

Bowen Qi
School of Mechanical and Automotive Engineering, University of Ulsan, South Korea.

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