MULTI-3: A GPU-enhanced meshfree simulation framework for multi-track, multi-layer, and multi-material laser powder bed fusion processes

IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING
C. Lüthi, M. Bambach, M. Afrasiabi
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引用次数: 0

Abstract

Multi-material laser powder bed fusion (MM-LPBF), especially with materials of contrasting properties, presents both exciting potential and significant challenges in additive manufacturing. Detailed modeling is essential for further development of these processes due to the difficulty of in-situ monitoring and control of inter-material interfaces, given the small spatiotemporal scales involved. To address this need, we present MULTI-3, a high-fidelity, GPU-accelerated computational framework designed to simulate MM-LPBF processes, including multiple tracks, layers, and materials. MULTI-3 combines a hybrid meshfree approach, leveraging a modified discrete element method (DEM) for efficient powder application and a stabilized smoothed particle hydrodynamics (SPH) technique to capture melt pool dynamics. The framework’s GPU-accelerated runtime enables the completion of a single-track LPBF simulation with modest resolution in about 29 min using a single consumer-grade graphics card. We demonstrate MULTI-3’s capabilities through a series of LPBF simulations with 316L and CuCr1Zr, employing varied deposition patterns and geometries to analyze melt pool behavior and morphology across different processing conditions. Results from these numerical experiments indicate that: (1) the SPH-DEM approach effectively addresses material mixing and interface challenges in MM-LPBF, primarily due to its Lagrangian formulation; (2) diffusion effects on interfacial material concentration remain negligible at the powder scale within the millimeter range of processing; and (3) high-fidelity, meshfree simulations of MM-LPBF processes involving multiple tracks and layers are currently achievable only through parallel computing.
MULTI-3:一个gpu增强的多轨道、多层和多材料激光粉末床融合过程的无网格仿真框架
多材料激光粉末床熔融技术(MM-LPBF),特别是具有不同性能的材料,在增材制造中具有令人兴奋的潜力和重大的挑战。详细的建模对于这些过程的进一步发展至关重要,因为考虑到所涉及的小时空尺度,很难对材料间界面进行原位监测和控制。为了满足这一需求,我们提出了MULTI-3,一个高保真,gpu加速的计算框架,旨在模拟MM-LPBF过程,包括多个轨道,层和材料。MULTI-3结合了混合无网格方法,利用改进的离散元方法(DEM)进行有效的粉末应用,并利用稳定的光滑颗粒流体动力学(SPH)技术来捕获熔池动力学。该框架的gpu加速运行时可以使用单个消费级显卡在大约29分钟内完成中等分辨率的单轨道LPBF模拟。我们通过316L和CuCr1Zr的一系列LPBF模拟来证明MULTI-3的能力,采用不同的沉积模式和几何形状来分析不同加工条件下的熔池行为和形貌。数值实验结果表明:(1)SPH-DEM方法有效地解决了MM-LPBF中的材料混合和界面挑战,这主要得益于其拉格朗日公式;(2)在加工的毫米级粉体尺度上,扩散对界面物质浓度的影响可以忽略不计;(3)目前只有通过并行计算才能实现多道多层MM-LPBF过程的高保真、无网格模拟。
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来源期刊
Journal of Manufacturing Processes
Journal of Manufacturing Processes ENGINEERING, MANUFACTURING-
CiteScore
10.20
自引率
11.30%
发文量
833
审稿时长
50 days
期刊介绍: The aim of the Journal of Manufacturing Processes (JMP) is to exchange current and future directions of manufacturing processes research, development and implementation, and to publish archival scholarly literature with a view to advancing state-of-the-art manufacturing processes and encouraging innovation for developing new and efficient processes. The journal will also publish from other research communities for rapid communication of innovative new concepts. Special-topic issues on emerging technologies and invited papers will also be published.
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