2023-11-01 17:20:58
Of the various AM techniques (Additive Manufacturing), Laser Powder Bed Fusion (LPBF) stands out as a leading technology that allows complex metal parts to be formed in one go. However, LPBF is not without obstacles. One of the main obstacles is thermal deformations. In this article we will consider digital simulation (in Siemens NX) that uses the Inherent Strain Method (ISM) to predict and, where possible, anticipate thermal distortions in LPBF.
By: Rein van der Mast and Stef Rijkers
In LPBF, a high-energy laser melts very locally metal powder, building up 3D shapes layer by layer. The intense local heat input into the powder bed and directly below it, followed by rapid cooling, creates thermal gradients resulting in strong expansion and contraction of the material. This non-uniform cooling process can cause unwanted stresses and deformations in the workpiece, which can compromise dimensional accuracy and mechanical properties. It is relevant to note here, although not the main topic of this article, that the crystal structure can vary widely.
Simulatietools Siemens NX
At Fontys, students learn to work with simulation tools such as Siemens NX in their courses. The Engineering department implemented metal printing in 2014 and currently operates a modern Renishaw RenAM 500S metal printer at its facility on the Brainport Industries Campus (BIC) in Eindhoven, led by Rein van der Mast. In his graduation project, Bachelor student Stef Rijkers evaluated the effectiveness of modern simulation tools within Siemens NX Additive Manufacturing for optimizing LPBF prints. Without a Digital Twin encompassing the production process, there is often a need for optimization in the physical domain to achieve the best results. Such iterations are costly and time-consuming, while digital iterations would be significantly more efficient. Rijkers investigated the practical value of Digital Twins with regard to their predictive qualities in LPBF. Several reference parts were printed in 316L stainless steel and measured. The results, including some reference geometries from Siemens, allowed him to calibrate the system and improve the quality of the virtual representation of the print and the LBBF process.
Lees in Solutions Magazine the entire article regarding the research into the AM simulation tool in Siemens NX
The results achieved by these measures undeniably justify the investment of time and effort
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