Please use this identifier to cite or link to this item: https://doi.org/10.21256/zhaw-20143
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dc.contributor.authorMayer, Thomas-
dc.contributor.authorBrändle, Gabriel-
dc.contributor.authorSchönenberger, Andreas-
dc.contributor.authorEberlein, Robert-
dc.date.accessioned2020-06-11T14:03:16Z-
dc.date.available2020-06-11T14:03:16Z-
dc.date.issued2020-05-
dc.identifier.issn2405-8440de_CH
dc.identifier.urihttps://digitalcollection.zhaw.ch/handle/11475/20143-
dc.description.abstractSelective laser melting (SLM) is gaining increasing relevance in industry. Residual deformations and internal stresses caused by the repeated layerwise melting of the metal powder and transient cooling of the solidified layers still presents a significant challenge to the profitability and quality of the process. Excessive distortions or cracking may lead to expensive rejects. In practice, critical additively manufactured parts are either iteratively pre-compensated or redesigned based on production experience. To satisfy the need for improved understanding of this complex manufacturing process, CAE software providers have recently developed solutions to simulate the SLM process. This study focuses on the evaluation of two solutions by ANSYS, i.e. ANSYS Additive Print and ANSYS Additive Suite. ANSYS Additive Print (AAP), a user-oriented software, and ANSYS Additive Suite (AAS), a software requiring advanced experience with Finite Element Methods (FEM), are investigated and validated with regard to residual deformations. For the evaluation of the two programs, calibration and validation geometries were printed by SLM in Ti–6Al–4V and residual deformations have been measured by 3D scanning. The results have been used for the calibration of isotropic and anisotropic strain scaling factors in AAP, and for sensitivity analyses on the effect of basic model parameters in AAS. The actual validation of the programs is performed on the basis of different sample geometries with varying wall thickness and deformation characteristic. While both simulation approaches, AAP and AAS, are capable of predicting the qualitative characteristics of the residual deformations sufficiently well, accurate quantitative results are difficult to obtain. AAP is more accessible and yields accurate results within the calibrated regime. Extrapolation to other geometries introduces uncertainties, however. AAS, on the other hand, features a sounder physical basis and therefore allows for a more robust extrapolation. Numerical efforts and modelling uncertainties as well as requirements for an extensive set of material parameters reduce its practicality, however. More appropriate calibration geometries, continuing extension of a more reliable material database, improved user guidelines and increased numerical efficiency are key in the future establishment of the process simulation approaches in the industrial practice.de_CH
dc.language.isoende_CH
dc.publisherElsevierde_CH
dc.relation.ispartofHeliyonde_CH
dc.rightshttp://creativecommons.org/licenses/by-nc-nd/3.0/de_CH
dc.subjectAdditive Fertigungde_CH
dc.subjectSimulationde_CH
dc.subjectProzesssimulationde_CH
dc.subjectVerzugde_CH
dc.subject.ddc670: Industrielle und handwerkliche Fertigungde_CH
dc.titleSimulation and validation of residual deformations in additive manufacturing of metal partsde_CH
dc.typeBeitrag in wissenschaftlicher Zeitschriftde_CH
dcterms.typeTextde_CH
zhaw.departementSchool of Engineeringde_CH
zhaw.organisationalunitInstitut für Mechanische Systeme (IMES)de_CH
dc.identifier.doi10.1016/j.heliyon.2020.e03987de_CH
dc.identifier.doi10.21256/zhaw-20143-
zhaw.funding.euNode_CH
zhaw.issue5de_CH
zhaw.originated.zhawYesde_CH
zhaw.pages.starte03987de_CH
zhaw.publication.statuspublishedVersionde_CH
zhaw.volume6de_CH
zhaw.publication.reviewPeer review (Publikation)de_CH
zhaw.webfeedIndustrie 4.0de_CH
zhaw.webfeedMEM-Industriede_CH
zhaw.webfeedMetallische Materialiende_CH
zhaw.webfeedProzesstechnikde_CH
zhaw.webfeedSimulation and Optimizationde_CH
zhaw.webfeedAdditive Manufacturingde_CH
zhaw.author.additionalNode_CH
zhaw.display.portraitYesde_CH
Appears in collections:Publikationen School of Engineering

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Mayer, T., Brändle, G., Schönenberger, A., & Eberlein, R. (2020). Simulation and validation of residual deformations in additive manufacturing of metal parts. Heliyon, 6(5), e03987. https://doi.org/10.1016/j.heliyon.2020.e03987
Mayer, T. et al. (2020) ‘Simulation and validation of residual deformations in additive manufacturing of metal parts’, Heliyon, 6(5), p. e03987. Available at: https://doi.org/10.1016/j.heliyon.2020.e03987.
T. Mayer, G. Brändle, A. Schönenberger, and R. Eberlein, “Simulation and validation of residual deformations in additive manufacturing of metal parts,” Heliyon, vol. 6, no. 5, p. e03987, May 2020, doi: 10.1016/j.heliyon.2020.e03987.
MAYER, Thomas, Gabriel BRÄNDLE, Andreas SCHÖNENBERGER und Robert EBERLEIN, 2020. Simulation and validation of residual deformations in additive manufacturing of metal parts. Heliyon. Mai 2020. Bd. 6, Nr. 5, S. e03987. DOI 10.1016/j.heliyon.2020.e03987
Mayer, Thomas, Gabriel Brändle, Andreas Schönenberger, and Robert Eberlein. 2020. “Simulation and Validation of Residual Deformations in Additive Manufacturing of Metal Parts.” Heliyon 6 (5): e03987. https://doi.org/10.1016/j.heliyon.2020.e03987.
Mayer, Thomas, et al. “Simulation and Validation of Residual Deformations in Additive Manufacturing of Metal Parts.” Heliyon, vol. 6, no. 5, May 2020, p. e03987, https://doi.org/10.1016/j.heliyon.2020.e03987.


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