Wen Dong, Basil J. Paudel, Hao Deng, Shane Garner, Albert C. To
{"title":"Data-driven distortion compensation for laser powder bed fusion process using Gaussian process regression and inherent strain method","authors":"Wen Dong, Basil J. Paudel, Hao Deng, Shane Garner, Albert C. To","doi":"10.1016/j.matdes.2024.113063","DOIUrl":null,"url":null,"abstract":"<div><p>The repeated melting and solidification cycles in the laser powder bed fusion (L-PBF) process lead to significant thermal gradients, resulting in notable distortion in the as-built part. Distortion compensation methods, which pre-deform the part design so the as-built shape aligns with the target, have been widely adopted to mitigate this issue. This research introduces a data-driven distortion compensation framework for the L-PBF process. It employs an experimentally-calibrated inherent strain method to generate a dataset and utilizes Gaussian process regression to create the compensated geometry. Experimental validation shows that the proposed method can reduce the maximum distortion by up to 82.5% for a lattice structure and 77.8% for a canonical part. Furthermore, the compensation results reveal that (1) the lumped layer thickness in finite element models has little impact on simulated distortion reduction but can notably affect the experimental reduction; (2) discrepancies between simulated and experimental compensation performance are largely attributed to the curvy surfaces with sharp transitions in trial and compensated shapes, a result of pre-deforming the design; (3) the number of trial geometries considerably affects the effectiveness of compensation, while the number of deformation states does not have a statistically significant impact.</p></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":null,"pages":null},"PeriodicalIF":7.6000,"publicationDate":"2024-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S0264127524004374/pdfft?md5=92d512c575bd11c7ded7eb4653841733&pid=1-s2.0-S0264127524004374-main.pdf","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Materials & Design","FirstCategoryId":"88","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0264127524004374","RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"MATERIALS SCIENCE, MULTIDISCIPLINARY","Score":null,"Total":0}
引用次数: 0
Abstract
The repeated melting and solidification cycles in the laser powder bed fusion (L-PBF) process lead to significant thermal gradients, resulting in notable distortion in the as-built part. Distortion compensation methods, which pre-deform the part design so the as-built shape aligns with the target, have been widely adopted to mitigate this issue. This research introduces a data-driven distortion compensation framework for the L-PBF process. It employs an experimentally-calibrated inherent strain method to generate a dataset and utilizes Gaussian process regression to create the compensated geometry. Experimental validation shows that the proposed method can reduce the maximum distortion by up to 82.5% for a lattice structure and 77.8% for a canonical part. Furthermore, the compensation results reveal that (1) the lumped layer thickness in finite element models has little impact on simulated distortion reduction but can notably affect the experimental reduction; (2) discrepancies between simulated and experimental compensation performance are largely attributed to the curvy surfaces with sharp transitions in trial and compensated shapes, a result of pre-deforming the design; (3) the number of trial geometries considerably affects the effectiveness of compensation, while the number of deformation states does not have a statistically significant impact.
期刊介绍:
Materials and Design is a multi-disciplinary journal that publishes original research reports, review articles, and express communications. The journal focuses on studying the structure and properties of inorganic and organic materials, advancements in synthesis, processing, characterization, and testing, the design of materials and engineering systems, and their applications in technology. It aims to bring together various aspects of materials science, engineering, physics, and chemistry.
The journal explores themes ranging from materials to design and aims to reveal the connections between natural and artificial materials, as well as experiment and modeling. Manuscripts submitted to Materials and Design should contain elements of discovery and surprise, as they often contribute new insights into the architecture and function of matter.