Thermo-Mechanical Modeling of Additive Manufacturing

Thermo-mechanical Modeling of Additive Manufacturing provides the background, methodology and description of modeling techniques to enable the reader to perform their own accurate and reliable simulations of any additive process. Part I provides an in depth introduction to the fundamentals of additive manufacturing modeling, a description of adaptive mesh strategies, a thorough description of thermal losses and a discussion of residual stress and distortion. Part II applies the engineering fundamentals to direct energy deposition processes including laser cladding, LENS builds, large electron beam parts and an exploration of residual stress and deformation mitigation strategies. Part III concerns the thermo-mechanical modeling of powder bed processes with a description of the heat input model, classical thermo-mechanical modeling, and part scale modeling. The book serves as an essential reference for engineers and technicians in both industry and academia, performing both research and full-scale production. Additive manufacturing processes are revolutionizing production throughout industry. These technologies enable the cost-effective manufacture of small lot parts, rapid repair of damaged components and construction of previously impossible-to-produce geometries. However, the large thermal gradients inherent in these processes incur large residual stresses and mechanical distortion, which can push the finished component out of engineering tolerance. Costly trial-and-error methods are commonly used for failure mitigation. Finite element modeling provides a compelling alternative, allowing for the prediction of residual stresses and distortion, and thus a tool to investigate methods of failure mitigation prior to building. Provides understanding of important components in the finite element modeling of additive manufacturing processes necessary to obtain accurate resultsOffers a deeper understanding of how the thermal gradients inherent in additive manufacturing induce distortion and residual stresses, and how to mitigate these undesirable phenomenaIncludes a set of strategies for the modeler to improve computational efficiency when simulating various additive manufacturing processesServes as an essential reference for engineers and technicians in both industry and academia INDICE: Part I - The fundamentals of additive manufacturing modeling 1. Introduction 2. The Finite Element Method for the Thermo-Mechanical Modeling of Additive Manufacturing Processes Part II Thermomechanical modeling of Direct Energy Deposition processes 3. Convection Boundary Losses During Laser Cladding 4. Conduction Losses due to Part Fixturing During Laser Cladding 5. Modeling Microstructure and Material Properties of AM Processes Using the FE Method 6. Thermo-mechanical Modeling of LENS Builds 7. Residual Stress and Distortion Modeling of Electron Beam Direct Manufacturing Ti-6Al-4V 8. Thermo-mechanical Modeling of Large Electron Beam Builds 9. Mitigation of Distortion in Large Additive Manufacturing Parts Part III Thermomechanical modeling of powder bed processes 10. Development and Numerical Verification of an Adaptive Mesh Coarsening Strategy for Simulating Laser Powder Bed Fusion Processes 11, Experimental Validation for In Situ Distortion Modeling of the Laser Powder Bed Fusion Process 12. Experimental Validation of Multi-scale Thermo-mechanical Modeling of Laser Powder Bed Fusion Processes 13. The Effect of Scan Pattern on the Development of Distortion and Residual Stress in Laser Powder Bed Fusion Components Appendix A.1. Temperature dependent properties A.1.1 Aluminum 6061 A.1.2 Inconel 625 A.1.3 Inconel 718 A.1.4 Stainless Steel AISI 304 A.1.5 Ti-6Al-4V

• ISBN: 978-0-12-811820-7
• Editorial: Butterworth-Heinemann
• Encuadernacion: Rústica
• Páginas: 256
• Fecha Publicación: 01/09/2017
• Nº Volúmenes: 1
• Idioma: Inglés