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A novel smoothed particle hydrodynamics method for multi-physics simulation of laser powder bed fusion

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Abstract

In this work, we propose an efficient smoothed particle hydrodynamics (SPH) method for simulating laser powder bed fusion (LPBF). The multi-physics process of LPBF, including the heat transfer and phase change with complex boundaries, is accurately resolved by a novel heat source model and a modified continuous surface force based on a corrected surface delta function. Moreover, we also develop an efficient tensile instability control algorithm for preventing the pressure oscillations. The present method is implemented in a GPU-accelerated framework, and its performance is well demonstrated by simulating the LPBF processes with both single-layer and multi-layer powder beds (with the help of surface reconstruction). The numerical results are compared well with the experimental ones which clearly verify the ability of the present method in capturing the complex physical phenomenon of LPBF.

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Acknowledgements

This work has been partially supported by the National Natural Science Foundation of China [Grant Nos. 12032002 and U22A20256]; the National Natural Science Foundation of Beijing [No. L212023]; and the Sino-German Mobility Programme [No. M-0210].

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Authors and Affiliations

  1. College of Engineering, Peking University, Beijing, 100871, China

    Yibo Ma, Xu Zhou, Fan Zhang & Moubin Liu

  2. State Key Laboratory for Turbulence and Complex Systems, Peking University, Beijing, 100871, China

    Yibo Ma, Xu Zhou & Moubin Liu

  3. School of Mathematics and Physics, University of Science and Technology Beijing, Beijing, 100083, China

    Fan Zhang

  4. AM Technologiezentrum 8, 86159, Augsburg, Germany

    Christian Weißenfels

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  1. Yibo Ma
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Ma, Y., Zhou, X., Zhang, F. et al. A novel smoothed particle hydrodynamics method for multi-physics simulation of laser powder bed fusion. Comput Mech (2024). https://doi.org/10.1007/s00466-024-02465-5

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