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Damage Modeling in Metal Additive Manufacturing Process Simulations.

Record Type:	Language materials, manuscript : Monograph/item
Title/Author:	Damage Modeling in Metal Additive Manufacturing Process Simulations./
Author:	Fietek, Carter J.
Description:	1 online resource (78 pages)
Notes:	Source: Masters Abstracts International, Volume: 84-08.
Contained By:	Masters Abstracts International84-08.
Subject:	Mechanical engineering. -
Online resource:	click for full text (PQDT)
ISBN:	9798374404913

Damage Modeling in Metal Additive Manufacturing Process Simulations.
Fietek, Carter J.

Damage Modeling in Metal Additive Manufacturing Process Simulations. - 1 online resource (78 pages)

Source: Masters Abstracts International, Volume: 84-08.

Thesis (M.S.M.E.)--New Mexico State University, 2022.

Includes bibliographical references

Additive manufacturing (AM) has become one of the industry's most revolutionary technologies for the fabrication of metal parts. Powder bed fusion is an additive manufacturing method that uses a laser or electron beam to melt and fuse raw metal powder into a complex three-dimensional part. This process involves rapid heating and solidification, resulting in high thermal gradients causing undesired residual stress and distortion that may significantly decrease the final product's integrity. The buildup of residual stresses can cause damage and eventual failure in service. This study investigates the impact of high thermal gradients, coupled with structural deformation, on the development of residual stress, distortions and ductile damage for parts manufactured through powder bed fusion. Commercial finite element analysis (FEA) software, Abaqus, was used for the sequentially coupled thermo-mechanical analysis. The analysis considers the layer-by-layer scanned path (tool path) generated for each 3D geometry. A user-defined material script (UMAT) was developed to model nonlinear material behavior and the propagation of ductile damage based on a Johnson-Cook failure model in the structural simulation. Heat transfer in additive manufacturing is time-dependent, and the resulting temperature distribution will typically be non-uniform. Therefore, the temperature history is first calculated in a transient heat transfer analysis and introduced as a predefined field in the subsequent structural analysis. After the thermal analysis is completed, the quasi-static stress analysis is completed for each time step considering the temperature prescribed, the new layer activated, and temperature-dependent material. The plastic deformation, temperature and strain rate then impact the accumulation of damage in the part. This method for predicting residual stress and distortions within an AM part accurately predict the final manufactured product. Results from these analyses are employed to evaluate the damage initiation of 3D-printed components.

Electronic reproduction.
Ann Arbor, Mich. :
ProQuest,
2024

Mode of access: World Wide Web

ISBN: 9798374404913Subjects--Topical Terms:

557493
Mechanical engineering.
Subjects--Index Terms:

Additive manufacturingIndex Terms--Genre/Form:

554714
Electronic books.

Damage Modeling in Metal Additive Manufacturing Process Simulations.
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520 $a Additive manufacturing (AM) has become one of the industry's most revolutionary technologies for the fabrication of metal parts. Powder bed fusion is an additive manufacturing method that uses a laser or electron beam to melt and fuse raw metal powder into a complex three-dimensional part. This process involves rapid heating and solidification, resulting in high thermal gradients causing undesired residual stress and distortion that may significantly decrease the final product's integrity. The buildup of residual stresses can cause damage and eventual failure in service. This study investigates the impact of high thermal gradients, coupled with structural deformation, on the development of residual stress, distortions and ductile damage for parts manufactured through powder bed fusion. Commercial finite element analysis (FEA) software, Abaqus, was used for the sequentially coupled thermo-mechanical analysis. The analysis considers the layer-by-layer scanned path (tool path) generated for each 3D geometry. A user-defined material script (UMAT) was developed to model nonlinear material behavior and the propagation of ductile damage based on a Johnson-Cook failure model in the structural simulation. Heat transfer in additive manufacturing is time-dependent, and the resulting temperature distribution will typically be non-uniform. Therefore, the temperature history is first calculated in a transient heat transfer analysis and introduced as a predefined field in the subsequent structural analysis. After the thermal analysis is completed, the quasi-static stress analysis is completed for each time step considering the temperature prescribed, the new layer activated, and temperature-dependent material. The plastic deformation, temperature and strain rate then impact the accumulation of damage in the part. This method for predicting residual stress and distortions within an AM part accurately predict the final manufactured product. Results from these analyses are employed to evaluate the damage initiation of 3D-printed components.
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