Prediction of recoater crash in laser powder bed fusion additive manufacturing using graph theory thermomechanical modeling

Md Humaun Kobir, Reza Yavari, Alexander R. Riensche, Benjamin D. Bevans, Leandro Castro, Kevin D. Cole, Prahalada Rao

Research output: Contribution to journalArticlepeer-review

1 Scopus citations

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.

Original languageEnglish (US)
JournalProgress in Additive Manufacturing
DOIs
StateAccepted/In press - 2022

Keywords

  • Graph theory
  • Laser powder bed fusion
  • Recoater crash
  • Thermomechanical modeling

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

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