Abstract
In this work, the particle finite element method (PFEM) is extended to simulate additive manufacturing processes in a variety of different complicated geometries. A three-dimensional α-shape approach is used to carry out the material addition procedure. It overcomes the limitation of merely employing the traditional element birth and death technique and reduces the degrees-of-freedom compared to this technique. Furthermore, numerical examples are used to evaluate and demonstrate the applicability of the PFEM method for additive manufacturing within the framework of a weakly coupled thermoelasticity formulation. During additive manufacturing operations, deflections, stresses, and temperature are computed using a user-defined implementation in FEniCS.
References
1.
Schoinochoritis
, B.
, Chantzis
, D.
, and Salonitis
, K.
, 2017
, “Simulation of Metallic Powder Bed Additive Manufacturing Processes With the Finite Element Method: A Critical Review
,” Proc. Inst. Mech. Eng. B. J. Manuf.
, 231
(1
), pp. 96
–117
. 2.
Körner
, C.
, Bauereiß
, A.
, and Attar
, E.
, 2013
, “Fundamental Consolidation Mechanisms During Selective Beam Melting of Powders
,” Modell. Simul. Mater. Sci. Eng.
, 21
(8
), p. 085011
. 3.
Bauereiß
, A.
, Scharowsky
, T.
, and Körner
, C.
, 2014
, “Defect Generation and Propagation Mechanism During Additive Manufacturing by Selective Beam Melting
,” J. Mater. Process. Technol.
, 214
(11
), pp. 2522
–2528
. 4.
Chen
, T.
, and Zhang
, Y.
, 2004
, “Numerical Simulation of Two-Dimensional Melting and Resolidification of a Two-Component Metal Powder Layer in Selective Laser Sintering Process
,” Numerical Heat Transfer, Part A: Appl.
, 46
(7
), pp. 633
–649
. 5.
Dai
, D.
, and Gu
, D.
, 2014
, “Thermal Behavior and Densification Mechanism During Selective Laser Melting of Copper Matrix Composites: Simulation and Experiments
,” Mater. Des.
, 55
, pp. 482
–491
. 6.
Russell
, M.
, Souto-Iglesias
, A.
, and Zohdi
, T.
, 2018
, “Numerical Simulation of Laser Fusion Additive Manufacturing Processes Using the SPH Method
,” Comput. Meth. Appl. Mech. Eng.
, 341
, pp. 163
–187
. 7.
Parteli
, E. J.
, and Pöschel
, T.
, 2016
, “Particle-Based Simulation of Powder Application in Additive Manufacturing
,” Powder Technol.
, 288
, pp. 96
–102
. 8.
Chen
, H.
, Sun
, Y.
, Yuan
, W.
, Pang
, S.
, Yan
, W.
, and Shi
, Y.
, 2022
, “A Review on Discrete Element Method Simulation in Laser Powder Bed Fusion Additive Manufacturing
,” Chin. J. Mech. Eng.: Additive Manuf. Frontiers
, 1
(1
), p. 100017
. 9.
Hussein
, A.
, Hao
, L.
, Yan
, C.
, and Everson
, R.
, 2013
, “Finite Element Simulation of the Temperature and Stress Fields in Single Layers Built Without-Support in Selective Laser Melting
,” Mater. Des. (1980–2015)
, 52
, pp. 638
–647
. 10.
O nate
, E.
, Idelsohn
, S. R.
, Del Pin
, F.
, and Aubry
, R.
, 2004
, “The Particle Finite Element Method–An Overview
,” Int. J. Comput. Meth.
, 1
(2
), pp. 267
–307
. 11.
Oliver
, J.
, Cante
, J.
, Weyler
, R.
, González
, C.
, and Hernández
, J.
, 2007
, “Particle Finite Element Methods in Solid Mechanics Problems,” Computational Plasticity
, E.
Oñate
, and R.
Owen
, eds., Springer Netherlands
, Dordrecht
, pp. 87
–103
.12.
Oñate
, E.
, Franci
, A.
, and Carbonell
, J. M.
, 2014
, “A Particle Finite Element Method for Analysis of Industrial Forming Processes
,” Comput. Mech.
, 54
(1
), pp. 85
–107
. 13.
Rodríguez
, J.
, 2014
, “Numerical Modeling of Metal Cutting Processes Using the Particle Finite Element Method (PFEM),” Universitat Politècnica de Catalunya (UPC), Barcelona.14.
Rodriguez
, J.
, Carbonell
, J. M.
, Cante
, J.
, and Oliver
, J.
, 2016
, “The Particle Finite Element Method (PFEM) in Thermo-Mechanical Problems
,” Int. J. Numer. Meth. Eng.
, 107
(9
), pp. 733
–785
. 15.
Rodríguez
, J.
, Jonsén
, P.
, and Svoboda
, A.
, 2017
, “Simulation of Metal Cutting Using the Particle Finite-Element Method and a Physically Based Plasticity Model
,” Comput. Particle Mech.
, 4
(1
), pp. 35
–51
. 16.
Rodríguez
, J. M.
, Carbonell
, J. M.
, Cante
, J.
, and Oliver
, J.
, 2017
, “Continuous Chip Formation in Metal Cutting Processes Using the Particle Finite Element Method (PFEM)
,” Int. J. Solids. Struct.
, 120
, pp. 81
–102
. 17.
Rodríguez
, J.
, Carbonell
, J.
, and Jonsen
, P.
, 2020
, “Numerical Methods for the Modelling of Chip Formation
,” Arch. Comput. Meth. Eng.
, 27
(2
), pp. 387
–412
.18.
Rodriguez
, J.
, Larsson
, S.
, Carbonell
, J.
, and Jons’en
, P.
, 2021
, “Implicit Or Explicit Time Integration Schemes in the PFEM Modeling of Metal Cutting Processes
,” Comput. Part. Mech.
, 9
(4
), pp. 1
–25
. 19.
Onate
, E.
, Rossi
, R.
, Idelsohn
, S. R.
, and Butler
, K. M.
, 2010
, “Melting and Spread of Polymers in Fire With the Particle Finite Element Method
,” Int. J. Numer. Meth. Eng.
, 81
(8
), pp. 1046
–1072
. 20.
Onate
, E.
, Marti
, J.
, Ryzhakov
, P.
, Rossi
, R.
, and Idelsohn
, S. R.
, 2017
, “Analysis of the Melting, Burning and Flame Spread of Polymers With the Particle Finite Element Method
,” Comput. Assist. Meth. Eng. Sci.
, 20
(3
), pp. 165
–184
.21.
Yuan
, W.-H.
, Zhang
, W.
, Dai
, B.
, and Wang
, Y.
, 2019
, “Application of the Particle Finite Element Method for Large Deformation Consolidation Analysis
,” Eng. Comput.
, 36
(9
), pp. 3138
–3163
. 22.
Zhang
, X.
, Krabbenhoft
, K.
, Pedroso
, D.
, Lyamin
, A.
, Sheng
, D.
, Da Silva
, M. V.
, and Wang
, D.
, 2013
, “Particle Finite Element Analysis of Large Deformation and Granular Flow Problems
,” Comput. Geotechnics
, 54
, pp. 133
–142
. 23.
Cante
, J.
, Davalos
, C.
, Hernandez
, J.
, Oliver
, J.
, Jonsén
, P.
, Gustafsson
, G.
, and Häggblad
, H.-Å.
, 2014
, “PFEM-Based Modeling of Industrial Granular Flows
,” Comput. Part. Mech.
, 1
(1
), pp. 47
–70
. 24.
Dávalos
, C.
, Cante
, J.
, Hernández
, J.
, and Oliver
, J.
, 2015
, “On the Numerical Modeling of Granular Material Flows Via the Particle Finite Element Method (PFEM)
,” Int. J. Solids Struct.
, 71
, pp. 99
–125
. 25.
Reinold
, J.
, and Meschke
, G.
, 2018
, “Particle Finite Element Simulation of Fresh Concrete for 3D Printing Applications,” Forschungskolloquium 2018 Grasellenbach
, J.
Schneider
, and N.
Kiziltoprak
, eds., Springer Fachmedien Wiesbaden
, Wiesbaden
, pp. 68
–70
.26.
Reinold
, J.
, Nerella
, V.
, Mechtcherine
, V.
, and Meschke
, G.
, 2019
, “Particle Finite Element Simulation of Extrusion Proceses of Fresh Concrete During 3D-Concrete-Printing
,” Sim-AM 2019: II International Conference on Simulation for Additive Manufacturing
, Pavia, Italy
, Sept. 11–13
, CIMNE, pp. 428
–439
.27.
Reinold
, J.
, Nerella
, V. N.
, Mechtcherine
, V.
, and Meschke
, G.
, 2022
, “Extrusion Process Simulation and Layer Shape Prediction During 3D-Concrete-Printing Using the Particle Finite Element Method
,” Autom. Constr.
, 136
, p. 104173
. 28.
Sabel
, M.
, Sator
, C.
, and Müller
, R.
, 2014
, “A Particle Finite Element Method for Machining Simulations
,” Comput. Mech.
, 54
(1
), pp. 123
–131
. 29.
Lee
, D.-T.
, and Schachter
, B. J.
, 1980
, “Two Algorithms for Constructing a Delaunay Triangulation
,” Int. J. Computer Inform. Sci.
, 9
(3
), pp. 219
–242
. 30.
Edelsbrunner
, H.
, and Mücke
, E. P.
, 1994
, “Three-Dimensional Alpha Shapes
,” ACM Trans. Graphics (TOG)
, 13
(1
), pp. 43
–72
. 31.
Alnæs
, M.
, Blechta
, J.
, Hake
, J.
, Johansson
, A.
, Kehlet
, B.
, Logg
, A.
, Richardson
, C.
, Ring
, J.
, Rognes
, M. E.
, and Wells
, G. N.
, 2015
, “The Fenics Project Version 1.5
,” Arch. Numer. Softw.
, 3
(100
), pp. 9
–23
. 32.
Luo
, C.
, Qiu
, J.
, Yan
, Y.
, Yang
, J.
, Uher
, C.
, and Tang
, X.
, 2018
, “Finite Element Analysis of Temperature and Stress Fields During the Selective Laser Melting Process of Thermoelectric SNTE
,” J. Mater. Process. Technol.
, 261
, pp. 74
–85
. 33.
Li
, C.
, Liu
, Z.
, Fang
, X.
, and Guo
, Y.
, 2018
, “Residual Stress in Metal Additive Manufacturing
,” Procedia Cirp
, 71
, pp. 348
–353
. Copyright © 2023 by ASME
You do not currently have access to this content.
