@article{4b14f2f3a93f45ad9376fe37ab1755cf,
title = "Prediction of recoater crash in laser powder bed fusion additive manufacturing using graph theory thermomechanical modeling",
abstract = "The objective of this work is to predict a type of thermal-induced process failure called recoater crash that occurs frequently during laser powder bed fusion (LPBF) additive manufacturing. Rapid and accurate thermomechanical simulations are valuable for LPBF practitioners to identify and correct potential issues in the part design and processing conditions that may cause recoater crashes. In this work, to predict the likelihood of a recoater crash (recoater contact or impact) we develop and apply a computationally efficient thermomechanical modeling approach based on graph theory. The accuracy and computational efficiency of the approach is demonstrated by comparison with both non-proprietary finite element analysis (Abaqus), and a proprietary LPBF simulation software (Autodesk Netfabb). Based on both numerical (verification) and experimental (validation) studies, the proposed approach is found to be 5 to 6 times faster than the non-proprietary finite element modeling and has the same order of computational time as a commercial simulation software (Netfabb) without sacrificing prediction accuracy.",
keywords = "Graph theory, Laser powder bed fusion, Recoater crash, Thermomechanical modeling",
author = "Kobir, {Md Humaun} and Reza Yavari and Riensche, {Alexander R.} and Bevans, {Benjamin D.} and Leandro Castro and Cole, {Kevin D.} and Prahalada Rao",
note = "Funding Information: Prahalada Rao acknowledges funding from the Department of Energy (DOE), Office of Science, under Grant number DE-SC0021136, and the National Science Foundation (NSF) [Grant numbers CMMI-1719388, OIA-1929172 CMMI-1920245, CMMI-1739696, CMMI-1752069, PFI-TT 2044710, ECCS 2020246] for funding his research program. This work espousing the concept of graph theory thermal modeling for predicting deformation was funded through the NSF Grant OIA 1929172 (Program Officer: Jose Colom). The experiments at Edison Welding Institute used in this work were made possible by the foregoing OIA grant. This grant also supported the graduate work of Dr. Reza Yavari, Mr. Alex Riensche, Mr. Ben Bevans, and Mr. M. H. Kobir. The concept of graph theory thermal modeling was first proposed in CMMI-1752069 (Program Officer: Kevin Chou). The NSF Intern supplement to the foregoing NSF grant (Program officer: Prakash Balan) allowed Dr. Yavari to conduct experiments on the Open Architecture LPBF platform at Edison Welding Institute. This work takes the first step towards commercialization of the graph theory thermal modeling approach through the NSF grant PFI-TT 2044710 (Program Officer: Samir Iqbal), which is currently supporting the graduate work of Mr. Alex Riensche, Mr. Ben Bevans, and Mr. Leandro Castro. The DoE grant DE-SC0021136 (Program Officer: Timothy Fitzsimmons) also supported the doctoral graduate work of Mr. Alex Riensche. and Mr. Ben Bevans. Kevin Cole acknowledges funding from DE-SC0021136 and PFI-TT 2044710. Funding Information: Prahalada Rao acknowledges funding from the Department of Energy (DOE), Office of Science, under Grant number DE-SC0021136, and the National Science Foundation (NSF) [Grant numbers CMMI-1719388, OIA-1929172 CMMI-1920245, CMMI-1739696, CMMI-1752069, PFI-TT 2044710, ECCS 2020246] for funding his research program. This work espousing the concept of graph theory thermal modeling for predicting deformation was funded through the NSF Grant OIA 1929172 (Program Officer: Jose Colom). The experiments at Edison Welding Institute used in this work were made possible by the foregoing OIA grant. This grant also supported the graduate work of Dr. Reza Yavari, Mr. Alex Riensche, Mr. Ben Bevans, and Mr. M. H. Kobir. The concept of graph theory thermal modeling was first proposed in CMMI-1752069 (Program Officer: Kevin Chou). The NSF Intern supplement to the foregoing NSF grant (Program officer: Prakash Balan) allowed Dr. Yavari to conduct experiments on the Open Architecture LPBF platform at Edison Welding Institute. This work takes the first step towards commercialization of the graph theory thermal modeling approach through the NSF grant PFI-TT 2044710 (Program Officer: Samir Iqbal), which is currently supporting the graduate work of Mr. Alex Riensche, Mr. Ben Bevans, and Mr. Leandro Castro. The DoE grant DE-SC0021136 (Program Officer: Timothy Fitzsimmons) also supported the doctoral graduate work of Mr. Alex Riensche. and Mr. Ben Bevans. Kevin Cole acknowledges funding from DE-SC0021136 and PFI-TT 2044710. Publisher Copyright: {\textcopyright} 2022, The Author(s), under exclusive licence to Springer Nature Switzerland AG.",
year = "2023",
month = jun,
doi = "10.1007/s40964-022-00331-5",
language = "English (US)",
volume = "8",
pages = "355--380",
journal = "Progress in Additive Manufacturing",
issn = "2363-9512",
publisher = "Springer Verlag",
number = "3",
}