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Thermo-mechanical Modeling of Additive Manufacturing provides the background, methodology and description of modeling techniques to enable the reader to perform their own accura… Read more
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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.
Materials Scientists, Manufacturing Engineers, Design Engineers, Undergraduate and Graduate Students, Professors working in the additive manufacturing, 3D printing and finite element modeling fields
Part I The fundamentals of additive manufacturing modeling
1. An introduction to additive manufacturing processes and their modeling challenges
Michael Fielding Gouge, Pan Michaleris
2. The Finite Element Method for the Thermo-Mechanical Modeling of Additive Manufacturing Processes
Erik Denlinger, Jeff Irwin, Michael Fielding Gouge
Part II Thermomechanical modeling of Direct Energy Deposition processes
3. Convection Boundary Losses During Laser Cladding
Michael Fielding Gouge
4. Conduction Losses due to Part Fixturing During Laser Cladding
Michael Fielding Gouge
5. Microstructure and Material Properties of AM Builds
Allison Michelle Beese
6. Understanding microstructure evolution during additive manufacturing of metallic alloys using phase-field modeling
Yanzhou Ji, Lei Chen, Long-Qing Chen
7. Modeling Microstructure and Material Properties of AM Processes Using the FE Method
Jeff Irwin
8. Thermo-mechanical Modeling of Thin Wall Builds Using the Direct Process
Jarred Heigel
9. Residual Stress and Distortion Modeling of Electron Beam Direct Manufacturing Ti-6Al-4V
Erik Denlinger
10. Thermo-mechanical Modeling of Large Electron Beam Builds
Erik Denlinger
11. Mitigation of Distortion in Large Additive Manufacturing Parts
Erik Denlinger
Part III Thermomechanical modeling of powder bed processes
12. Development and Numerical Verification of an Adaptive Mesh Coarsening Strategy for Simulating Laser Powder Bed Fusion Processes
Erik Denlinge
13. Experimental Validation for In Situ Distortion Modeling of the Laser Powder Bed Fusion Process
Erik Denlinger
14. Scan Pattern Effects in Laser Powder Bed Fusion Processes: In Situ Measurements and Experimental Validation
Alexander Dunbar
15. Experimental Validation of Multi-scale Thermo-mechanical Modeling of Laser Powder Bed Fusion Processe
Jeff Irwin, Michael Fielding Gouge
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