Thermal modeling of variable process parameter effects in powder bed fusion using electron beam
ISSN: 1355-2546
Article publication date: 27 August 2024
Issue publication date: 18 November 2024
Abstract
Purpose
This study aims to develop a novel thermal modeling strategy to simulate electron beam powder bed fusion at part scale with machine-varying process parameters strategy. Single-bead and part-scale experiments and modeling were studied. Scanning strategies were described by the process controlling functions that enabled modeling.
Design/methodology/approach
The finite element analysis thermal model was used along with the powder bed fusion with electron beam experiments. The proposed strategy involves dividing a part into smaller sections and creating meso-scale models for each subsection. These meso-scale models take into consideration the variable process parameters, including power and velocity of the moving heat source, during part building. Subsequently, these models are integrated to perform partscale simulations, enabling more realistic predictions of thermal accumulation and resulting distortions. The model was built and validated with single-bead experiments and bulky parts with different features.
Findings
Single-bead experiments demonstrated an average error rate of 6%–24% for melt pool dimension prediction using the proposed meso-scale models with different scanning control functions. Part-scale simulations for three different geometries (cantilever beams with supports, bulk artifact and topology-optimized transfer arm) showed good agreement between modeled temperature changes and experimental deformation values.
Originality/value
This study presents a novel approach for electron beam powder bed fusion modeling that leverages meso-scale models to capture the influence of variable process parameters on part quality. This strategy offers improved accuracy for predicting part geometry and identifying potential defects, leading to a more efficient additive manufacturing process.
Keywords
Acknowledgements
The authors thank Mutlu Karasoglu at Eskisehir Technical University for his help in the metallographic analysis. The authors also thank Alptug Taskın from AddPark for 3D scanning of the transfer arm part. In addition, the authors appreciate the guidance of Dr. Michael Gouge and Sualp Ozel on Netfabb Simulation practices. The authors gratefully acknowledge the Scientific and Technological Research Council of Türkiye (TÜBİTAK) through Project No. 218M717 for their financial support. Finally, the high-speed camera experiments were also supported by the Scientific Research Projects Department of Istanbul Technical University (Project No. MYL-2021-42967).
Conflict of interest: On behalf of all authors, the corresponding author states that there is no conflict of interest.
Citation
Kirim, B., Soylemez, E., Tan, E. and Yasa, E. (2024), "Thermal modeling of variable process parameter effects in powder bed fusion using electron beam", Rapid Prototyping Journal, Vol. 30 No. 10, pp. 2097-2112. https://doi.org/10.1108/RPJ-04-2024-0186
Publisher
:Emerald Publishing Limited
Copyright © 2024, Emerald Publishing Limited