Stress and distortion simulation of additive manufacturing process by high performance computing

Hui Huang; Jian Chen; Blair Carlson; Paul Crooker; Gregory Frederick; Hui Ping Wang; Zhili Feng

doi:10.1115/PVP201885045

Stress and distortion simulation of additive manufacturing process by high performance computing

Hui Huang, Jian Chen, Blair Carlson, Paul Crooker, Gregory Frederick, Hui Ping Wang, Zhili Feng

Materials Joining

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

8 Scopus citations

Abstract

Numerical simulation is an efficient way to better understand the thermal and mechanical evolution during metal additive manufacturing (AM) and to design and optimize the process. However, with today’s computational tools, pass-bypass thermal-mechanical numerical simulation of the metal AM process is extremely time-consuming. In this study, a new finite element code recently developed in house at Oak Ridge National Lab was used for additive manufacturing simulation. Our new code effectively utilizes GPU based high-performance computers to allow for realistic simulation of the transient thermal and mechanical response of materials during additive manufacturing. A benchmark study on a cylinder model by powder bed selective laser melting was carried out and distortion profile was compared to the experimental measurements. The accuracy and efficiency of the code was also demonstrated by analyzing a wire and arc additive manufacturing (WAAM) model which consists of a base plate and four deposited layers.

Original language	English
Title of host publication	Materials and Fabrication
Publisher	American Society of Mechanical Engineers (ASME)
ISBN (Electronic)	9780791851678
DOIs	https://doi.org/10.1115/PVP201885045
State	Published - 2018
Event	ASME 2018 Pressure Vessels and Piping Conference, PVP 2018 - Prague, Czech Republic Duration: Jul 15 2018 → Jul 20 2018

Publication series

Name	American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP
Volume	6A-2018
ISSN (Print)	0277-027X

Conference

Conference	ASME 2018 Pressure Vessels and Piping Conference, PVP 2018
Country/Territory	Czech Republic
City	Prague
Period	07/15/18 → 07/20/18

Funding

This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/ downloads/doe-public-access-plan) This work is funded by the DOE HPC4Mfg Program managed by Lawrence Livermore National Laboratory. R&D was performed at Oak Ridge National Laboratory. Oak Ridge National Laboratory is managed by UT-Battelle, LLC for the U.S. Department of Energy under Contract DE-AC05-00OR22725.

Funders	Funder number
US Department of Energy
U.S. Department of Energy	DE-AC05-00OR22725
Lawrence Livermore National Laboratory
Oak Ridge National Laboratory

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1115/PVP201885045

Cite this

Huang, H., Chen, J., Carlson, B., Crooker, P., Frederick, G., Wang, H. P., & Feng, Z. (2018). Stress and distortion simulation of additive manufacturing process by high performance computing. In Materials and Fabrication (American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP; Vol. 6A-2018). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/PVP201885045

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abstract = "Numerical simulation is an efficient way to better understand the thermal and mechanical evolution during metal additive manufacturing (AM) and to design and optimize the process. However, with today{\textquoteright}s computational tools, pass-bypass thermal-mechanical numerical simulation of the metal AM process is extremely time-consuming. In this study, a new finite element code recently developed in house at Oak Ridge National Lab was used for additive manufacturing simulation. Our new code effectively utilizes GPU based high-performance computers to allow for realistic simulation of the transient thermal and mechanical response of materials during additive manufacturing. A benchmark study on a cylinder model by powder bed selective laser melting was carried out and distortion profile was compared to the experimental measurements. The accuracy and efficiency of the code was also demonstrated by analyzing a wire and arc additive manufacturing (WAAM) model which consists of a base plate and four deposited layers.",

author = "Hui Huang and Jian Chen and Blair Carlson and Paul Crooker and Gregory Frederick and Wang, {Hui Ping} and Zhili Feng",

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Huang, H, Chen, J, Carlson, B, Crooker, P, Frederick, G, Wang, HP & Feng, Z 2018, Stress and distortion simulation of additive manufacturing process by high performance computing. in Materials and Fabrication. American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP, vol. 6A-2018, American Society of Mechanical Engineers (ASME), ASME 2018 Pressure Vessels and Piping Conference, PVP 2018, Prague, Czech Republic, 07/15/18. https://doi.org/10.1115/PVP201885045

Stress and distortion simulation of additive manufacturing process by high performance computing. / Huang, Hui; Chen, Jian; Carlson, Blair et al.
Materials and Fabrication. American Society of Mechanical Engineers (ASME), 2018. (American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP; Vol. 6A-2018).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AB - Numerical simulation is an efficient way to better understand the thermal and mechanical evolution during metal additive manufacturing (AM) and to design and optimize the process. However, with today’s computational tools, pass-bypass thermal-mechanical numerical simulation of the metal AM process is extremely time-consuming. In this study, a new finite element code recently developed in house at Oak Ridge National Lab was used for additive manufacturing simulation. Our new code effectively utilizes GPU based high-performance computers to allow for realistic simulation of the transient thermal and mechanical response of materials during additive manufacturing. A benchmark study on a cylinder model by powder bed selective laser melting was carried out and distortion profile was compared to the experimental measurements. The accuracy and efficiency of the code was also demonstrated by analyzing a wire and arc additive manufacturing (WAAM) model which consists of a base plate and four deposited layers.

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Huang H, Chen J, Carlson B, Crooker P, Frederick G, Wang HP et al. Stress and distortion simulation of additive manufacturing process by high performance computing. In Materials and Fabrication. American Society of Mechanical Engineers (ASME). 2018. (American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP). doi: 10.1115/PVP201885045

Stress and distortion simulation of additive manufacturing process by high performance computing

Abstract

Publication series

Conference

Funding

UN SDGs

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