Laser powder bed fusion (L-PBF) is widely used in automotive, aerospace, and biomedical applications thanks to its ability to produce complex geometries. In spite of its advantages, parts produced with this technology can show distortion due to the residual stresses developed during the printing process. For this reason, numerical simulations can be used to predict thermal gradients and residual stresses that can result in part distortion. Thus, instead of performing experimental tests and using a trial and error approach, it is possible to use numerical simulation to save time and material. In this work, the effect of laser power and scan speed on residual stress and part distortion was analysed using a commercial finite element analysis (FEA) software DEFORM-3D™ with a layer-by-layer approach. Moreover, the accuracy of the numerical model with respect to process parameters and the utilised mesh was also studied. The results obtained from the numerical simulation were compared to the actual distortions to evaluate the accuracy of the FEM model. The predicted distortions using FEM analysis well fit the trend of the measured ones. The accuracy of the numerical model increases by considering a finer mesh.

Palmeri, D., Pollara, G., Licari, R., Micari, F. (2023). Finite Element Method in L-PBF of Ti-6Al-4V: Influence of Laser Power and Scan Speed on Residual Stress and Part Distortion. METALS, 13(11) [10.3390/met13111907].

Finite Element Method in L-PBF of Ti-6Al-4V: Influence of Laser Power and Scan Speed on Residual Stress and Part Distortion

Palmeri, Dina
Primo
;
Pollara, Gaetano
Secondo
;
Licari, Roberto
Penultimo
;
Micari, Fabrizio
Ultimo
2023-11-19

Abstract

Laser powder bed fusion (L-PBF) is widely used in automotive, aerospace, and biomedical applications thanks to its ability to produce complex geometries. In spite of its advantages, parts produced with this technology can show distortion due to the residual stresses developed during the printing process. For this reason, numerical simulations can be used to predict thermal gradients and residual stresses that can result in part distortion. Thus, instead of performing experimental tests and using a trial and error approach, it is possible to use numerical simulation to save time and material. In this work, the effect of laser power and scan speed on residual stress and part distortion was analysed using a commercial finite element analysis (FEA) software DEFORM-3D™ with a layer-by-layer approach. Moreover, the accuracy of the numerical model with respect to process parameters and the utilised mesh was also studied. The results obtained from the numerical simulation were compared to the actual distortions to evaluate the accuracy of the FEM model. The predicted distortions using FEM analysis well fit the trend of the measured ones. The accuracy of the numerical model increases by considering a finer mesh.
19-nov-2023
Palmeri, D., Pollara, G., Licari, R., Micari, F. (2023). Finite Element Method in L-PBF of Ti-6Al-4V: Influence of Laser Power and Scan Speed on Residual Stress and Part Distortion. METALS, 13(11) [10.3390/met13111907].
File in questo prodotto:
File Dimensione Formato  
metals-13-01907.pdf

accesso aperto

Tipologia: Versione Editoriale
Dimensione 3.5 MB
Formato Adobe PDF
3.5 MB Adobe PDF Visualizza/Apri

I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.

Utilizza questo identificativo per citare o creare un link a questo documento: https://hdl.handle.net/10447/618133
Citazioni
  • ???jsp.display-item.citation.pmc??? ND
  • Scopus 0
  • ???jsp.display-item.citation.isi??? 0
social impact