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Analytical modeling of part distortion in metal additive manufacturing

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Abstract

This work presents an analytical modeling methodology for the prediction of part distortion in powder bed metal additive manufacturing (PBMAM). The presented model consists of analytical thermal modeling, thermal stress modeling, residual stress modeling, and distortion modeling. It has promising short computational efficiency without resorting to finite element analysis or any iteration-based simulations. The temperature profile is calculated using a moving point heat source solution and heat sink solution with consideration of heat input from a moving laser and heat loss from boundary heat transfer. The thermal stress is calculated from the temperature calculation using a thermal stress model considering thermal load, surface tension, and hydrostatic pressure. The residual stress is calculated from the thermal stress calculation using an elastoplastic relaxation procedure. The residual stress–induced part distortion is finally calculated from the calculated residual stress and residual strain using a surface displacement model. The calculated part distortion was validated to experimental measurement on a twin-cantilever part produced by PBMAM of Ti6Al4V. Close agreements were observed. The computational time was recorded less than 10 s. The high predictive accuracy and high computational efficiency allow the process parameter planning for distortion control and elimination through inverse analysis.

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Funding

This research project was financially supported by The Boeing Company.

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Authors and Affiliations

  1. George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, 801 Ferst Drive, Atlanta, GA, 30332, USA

    Jinqiang Ning, Maxwell Praniewicz, Wenjia Wang & Steven Y. Liang

  2. The Boeing Company, 499 Boeing Boulevard, Huntsville, AL, 35824, USA

    James R. Dobbs

Authors
  1. Jinqiang Ning
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  2. Maxwell Praniewicz
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  3. Wenjia Wang
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  4. James R. Dobbs
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  5. Steven Y. Liang
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Correspondence to Jinqiang Ning or Steven Y. Liang.

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Ning, J., Praniewicz, M., Wang, W. et al. Analytical modeling of part distortion in metal additive manufacturing. Int J Adv Manuf Technol 107, 49–57 (2020). https://doi.org/10.1007/s00170-020-05065-8

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  • DOI: https://doi.org/10.1007/s00170-020-05065-8

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