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The purpose of this paper is to develop an easy-to-implement and accurate fast boundary element method (BEM) for solving large-scale elastodynamic problems in frequency and time domains.

A newly developed kernel-independent fast multipole method (KIFMM) is applied to accelerating the evaluation of displacements, strains and stresses in frequency domain elastodynamic BEM analysis, in which the far-field interactions are evaluated efficiently utilizing equivalent densities and check potentials. Although there are six boundary integrals with unique kernel functions, by using the elastic theory, the authors managed to accelerate these six boundary integrals by KIFMM with the same kind of equivalent densities and check potentials. The boundary integral equations are discretized by Nyström method with curved quadratic elements. The method is further used to conduct the time-domain analysis by using the frequency-domain approach.

Numerical results show that by the fast BEM, high accuracy can be achieved and the computational complexity is brought down to linear. The performance of the present method is further demonstrated by large-scale simulations with more than two millions of unknowns in the frequency domain and one million of unknowns in the time domain. Besides, the method is applied to the topological derivatives for solving elastodynamic inverse problems.

An efficient KIFMM is implemented in the acceleration of the elastodynamic BEM. Combining with the Nyström discretization based on quadratic elements and the frequency-domain approach, an accurate and highly efficient fast BEM is achieved for large-scale elastodynamic frequency domain analysis and time-domain analysis.

High residual stress caused by the high temperature gradient brings undesired effects such as shrinkage and cracking in selective laser melting (SLM). The purpose of this study is to predict the residual stress distribution and the effect of process parameters on the residual stress of selective laser melted (SLMed) Inconel 718 thin-walled part.

A three-dimensional (3D) indirect sequentially coupled thermal–mechanical finite element model was developed to predict the residual stress distribution of SLMed Inconel 718 thin-walled part. The material properties dependent on temperature were taken into account in both thermal and mechanical analyses, and the thermal elastic–plastic behavior of the material was also considered.

The residual stress changes from compressive stress to tensile stress along the deposition direction, and the residual stress increases with the deposition height. The maximum stress occurs at both ends of the interface between the part and substrate, while the second largest stress occurs near the top center of the part. The residual stress increases with the laser power, with the maximum equivalent stress increasing by 21.79 per cent as the laser power increases from 250 to 450 W. The residual stress decreases with an increase in scan speed with a reduction in the maximum equivalent stress of 13.67 per cent, as the scan speed increases from 500 to 1,000 mm/s. The residual stress decreases with an increase in layer thickness, and the maximum equivalent stress reduces by 33.12 per cent as the layer thickness increases from 20 to 60µm.

The residual stress distribution and effect of process parameters on the residual stress of SLMed Inconel 718 thin-walled part are investigated in detail. This study provides a better understanding of the residual stress in SLM and constructive guidance for process parameters optimization.