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Title: Physics-based simulation models for digital twin development in laser powder bed fusion

Authors: Lihang Yang; Tuğrul Özel

Addresses: Department of Industrial and Systems Engineering, Manufacturing and Automation Research Laboratory, Rutgers University, Piscataway, New Jersey, 08854, USA ' Department of Industrial and Systems Engineering, Manufacturing and Automation Research Laboratory, Rutgers University, Piscataway, New Jersey, 08854, USA

Abstract: The digital twin for metal additive manufacturing is under development by unifying all simulation models integrated with the sensory observations for bi-directional data flow powered by machine learning. This paper presents physics-based simulation modelling for predicting the thermal field solution and molten pool geometry in laser powder bed fusion (L-PBF) process for Ti6Al4V, SS316L, and IN625 metal powders. Two-dimensional (2D) thermal field on the powder bed surface along the laser path and the hatch direction are computed for a moving laser heat source using implicit numerical formulation to understand the temperature rise during L-PBF process. The temperature field into the powder is computed using the temperature solution obtained along the laser path. The results are compared against the literature to corroborate the computed molten pool geometry. This numerical solution approach is found to be highly practical for computing thermal fields and suitable for digital twin development in metal additive manufacturing.

Keywords: additive manufacturing; physics-based simulation; digital twin; powder bed fusion; metal; finite element method; titanium; steel; nickel.

DOI: 10.1504/IJMMS.2021.10042371

International Journal of Mechatronics and Manufacturing Systems, 2021 Vol.14 No.2, pp.143 - 163

Received: 14 Apr 2021
Accepted: 05 Jul 2021

Published online: 19 Nov 2021 *

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