TY - JOUR

T1 - Design rules for additive manufacturing – Understanding the fundamental thermal phenomena to reduce scrap

AU - Yavari, M. Reza

AU - Cole, Kevin D.

AU - Rao, Prahalada K.

N1 - Funding Information:
One of the authors (PKR) thanks the National Science Foundation for funding his work through Grant Nos. CMMI-1719388, 1739696, and 1752069. Specifically, the development and application of graph theoretic approaches for process modeling and monitoring in metal AM processes presented in this paper was conceptualized and funded through CMMI-1752069 (CAREER).
Publisher Copyright:
© 2019 The Authors. Published by Elsevier B.V.

PY - 2019

Y1 - 2019

N2 - The goal of this work is to predict the effect of part geometry and process parameters on the direction and magnitude of heat flow ‒ heat flux ‒ in parts made using metal additive manufacturing (AM) processes. As a step towards this goal, the objective of this paper is to develop and apply the mathematical concept of heat diffusion over graphs to approximate the heat flux in metal AM parts as a function of their geometry. This objective is consequential to overcome the poor process consistency and part quality in AM. Currently, part build failure rates in metal AM often exceed 20%, the causal reason for this poor part yield in metal AM processes is ascribed to the nature of the heat flux in the part. For instance, constrained heat flux causes defects such as warping, thermal stress-induced cracking, etc. Hence, to alleviate these challenges in metal AM processes, there is a need for computational thermal models to estimate the heat flux, and thereby guide part design and selection of process parameters. Compared to moving heat source finite element analysis techniques, the proposed graph theoretic approach facilitates layer-by-layer simulation of the heat flux within a few minutes on a desktop computer, instead of several hours on a supercomputer.

AB - The goal of this work is to predict the effect of part geometry and process parameters on the direction and magnitude of heat flow ‒ heat flux ‒ in parts made using metal additive manufacturing (AM) processes. As a step towards this goal, the objective of this paper is to develop and apply the mathematical concept of heat diffusion over graphs to approximate the heat flux in metal AM parts as a function of their geometry. This objective is consequential to overcome the poor process consistency and part quality in AM. Currently, part build failure rates in metal AM often exceed 20%, the causal reason for this poor part yield in metal AM processes is ascribed to the nature of the heat flux in the part. For instance, constrained heat flux causes defects such as warping, thermal stress-induced cracking, etc. Hence, to alleviate these challenges in metal AM processes, there is a need for computational thermal models to estimate the heat flux, and thereby guide part design and selection of process parameters. Compared to moving heat source finite element analysis techniques, the proposed graph theoretic approach facilitates layer-by-layer simulation of the heat flux within a few minutes on a desktop computer, instead of several hours on a supercomputer.

KW - Additive Manufacturing

KW - Discrete Approximation

KW - Graph Theory

KW - Heat Equation

KW - Heat Flux

KW - Thermal Modeling

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U2 - 10.1016/j.promfg.2019.04.046

DO - 10.1016/j.promfg.2019.04.046

M3 - Conference article

AN - SCOPUS:85068577056

SN - 2351-9789

VL - 33

SP - 375

EP - 382

JO - Procedia Manufacturing

JF - Procedia Manufacturing

T2 - 16th Global Conference on Sustainable Manufacturing, GCSM 2018

Y2 - 2 October 2018 through 4 October 2018

ER -