Abstract
Metallic Additive Manufacturing (AM) has experienced increasing levels of demand due to its flexibility in producing complex geometries, bolstered by the growing availability of topology optimization methods. However, the multiple thermal cycles associated with these processes lead to the appearance of residual stresses that can worsen the dimensional accuracy and mechanical behavior of components. Consequently, efforts have been made to propose numerical models capable of distortion and residual stress prediction of parts manufactured through Laser Powder Bed Fusion (LPBF). This article introduces the mechanisms associated with residual stress generation and reviews known Finite Element Method (FEM) formulations of the additive manufacturing problem. Simulations are proposed and conduced that aim at comparing two software packages against each other and against experimental data; results are discussed, and lastly, conclusions are achieved.
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Acknowledgements
The project Add.Strength entitled “Enhanced Mechanical Properties in Additive Manufactured Components” funded by the Programa Operacional Competitividade e Internacionalização, and Programa Operacional Regional de Lisboa funded by FEDER and National Funds (FCT) is acknowledged (Reference PTDC/EME-EME/31307/2017). The BIC scholarship funded by the Add.Strength project is also acknowledged. The project “MAMTool—Machinability of Additive Manufactured Parts for Tooling Industry” funded by the Programa Operacional Competitividade e Internacionalização and the Programa Operacional Regional de Lisboa funded by FEDER and National Funds (FCT) is acknowledged (Reference PTDC/EME-EME/31895/2017). Finally, LAETA—Laboratório Associado de Energia, Transportes e Aeronáutica is acknowledged through the contract UIDP/50022/2020 supported by the FCT/MCTES involving PIDDAC national funds.
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Gil, J., Fiorentin, F., Pereira, J.C.R., de Jesus, A.M.P., Reis, A. (2022). Finite Element Analysis of Distortions, Residual Stresses and Residual Strains in Laser Powder Bed Fusion-Produced Components. In: Lesiuk, G., Szata, M., Blazejewski, W., Jesus, A.M.d., Correia, J.A. (eds) Structural Integrity and Fatigue Failure Analysis. VCMF 2020. Structural Integrity, vol 25. Springer, Cham. https://doi.org/10.1007/978-3-030-91847-7_14
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DOI: https://doi.org/10.1007/978-3-030-91847-7_14
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