Adaptive local-global multiscale approach for thermal simulation of the selective laser melting process
- Journal Article
Numerical simulation is a powerful tool for understanding the complex physics of metal additive manufacturing (MAM) processes and to provide guidelines for optimization of the process conditions. The fast kinetics and highly localized nature of the involved phenomena demand high levels of time and space discretization for MAM simulations which significantly increases the computational costs. The existing simplified simulation approaches apply gross approximations to overcome the numerical cost barrier. This study proposes a multiscale approach which breaks down the problem into two scales of local and global simulations. The method argues that a high level of discretization is only required for capturing the physics of fast-kinetics phenomena occurring in the vicinity of the melt-pool, while a much coarser discretization is applicable for the rest of the simulation domain. As a particular type of adaptive submodeling technique, the results of fine-mesh local simulations around the moving melt-pool are combined with the outcome of a coarse-mesh global solution to provide reliable predictions at a significantly reduced computational cost. The efficiency and reliability of the proposed idea has been evaluated for 2D thermal simulation of the selective laser melting process. The outcome of the exercise demonstrates that the methodology can reduce the computational cost of the simulations by an order of magnitude with minimal loss of accuracy. Show more
Journal / seriesAdditive Manufacturing
Pages / Article No.
SubjectAdditive manufacturing; Selective laser melting; Multiscale thermal modeling; Adaptive local-global simulation; Computational efficiency
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