Abstract:
This study focuses on the development of a 3D finite element model to simulate the dynamically powered-bed additive manufacturing process of soda lime glass. The model is created using ABAQUS software and involves performing non-linear transient thermal and structural analyses to understand the effects of different fusion process parameters, such as laser power and laser moving speed. A moving Gaussian distributed heat source model, implemented via deflux subroutine code, accounts for key phenomena such as thermal conditions and convection heat loss during the manufacturing process. The study also conducts a mesh sensitivity analysis to determine the optimal cell size and meshing technique for accurate results. The simulation calculates essential factors like temperature distribution, residual stresses, and strain, highlighting that a minimum of 30 W of laser power is adequate, but higher laser power results in increased residual stresses. Furthermore, the research demonstrates the significant influence of the laser’s speed and path on both the thermal and structural behavior of the material. To optimize the manufacturing process, alternative and unidirectional fusion path techniques are explored to reduce the temperature field, residual stresses, and deformation, ultimately improving the overall quality of the manufactured soda lime glass component.
Aim:
The aim of this study is to develop and simulate a 3D finite element model for the dynamically powered-bed additive manufacturing of soda lime glass. The study seeks to analyze the impact of key fusion process parameters, such as laser power and moving speed, on the thermal and structural characteristics of the material. By using ABAQUS software, the study aims to calculate the temperature field, residual stresses, and strain during the fusion process, and optimize the process through the investigation of fusion path techniques to reduce deformation and improve the quality of the final product.
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Objective:
The objectives of this study are to:
- Develop a 3D finite element model for simulating the additive manufacturing process of soda lime glass using a dynamically powered-bed approach.
- Perform non-linear transient thermal and structural analysis to assess the effects of laser power and laser moving speed on the material’s thermal and structural properties.
- Implement a moving Gaussian distributed heat source model in ABAQUS to simulate key phenomena such as thermal conditions and convection heat loss.
- Conduct a mesh sensitivity study to identify the optimal cell size and meshing technique for accurate results.
- Evaluate the temperature field, residual stresses, and strain during the fusion process and identify the minimum effective laser power for the process.
- Investigate the impact of laser moving speed and path on the structural and thermal results.
- Explore alternative and unidirectional fusion path techniques to reduce temperature variations, residual stresses, and deformation in the final product.
