Additive Manufacturing Stress Analysis Using Explicit FEM Heating Blocks
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Solution Overview
Problem
Existing methods for analyzing residual stress and deformation in additively manufactured objects are computationally intensive, making it difficult to efficiently analyze large-scale additive manufacturing processes.
Innovation Solution
The method employs dynamic explicit Finite Element Method (FEM) with a large temperature increment and an instantaneous surface heat source model to analyze residual stress and deformation in additively manufactured objects, significantly reducing computing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If static implicit FEM is used for thermal-elastic-plastic analysis of additively manufactured objects, then analysis accuracy is maintained, but computing time becomes excessively long for large-scale applications
Solution Approach 1:
The patent changes the fundamental parameter of the FEM approach from static implicit to dynamic explicit formulation. This parameter change allows the use of larger time increments and avoids the computational burden of solving large systems of linear equations at each step, thereby dramatically reducing computing time while maintaining acceptable accuracy for additive manufacturing analysis
Solution Approach 2:
The patent transitions from a static analysis framework to a dynamic explicit FEM framework. By incorporating dynamic effects and using explicit time integration, the method can handle the transient thermal and mechanical processes in additive manufacturing without requiring iterative solution of equilibrium equations, thus reducing computational time for large-scale problems
2Measurement precision
If experiment using actual product is conducted to examine residual stress and deformation, then accurate measurement can be obtained, but cost increases and measurement may be difficult
Solution Approach 1:
The patent creates a virtual copy of the additive manufacturing process through computer-based thermal-elastic-plastic analysis. Instead of physically measuring residual stress in actual products through expensive and difficult experiments, the method simulates the manufacturing process and predicts residual stress and deformation outcomes, providing accurate data without the costs and complexities of physical experimentation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for a substantial reduction in computing time required for analysis while maintaining accurate results, enabling more efficient additive manufacturing processes.
Implementation Method 1
The additively manufactured object is heated with an instantaneous surface heat source having a heat input quantity adjusted with respect to a heat input quantity applied when a moving heat source is used to heat the additively manufactured object
Implementation Method 2
additively manufactured object manufactured by depositing a molten material while solidifying the material
Data Source
AI summary
A displacement/stress computation unit computes residual stress and deformation by conducting a thermal-elastic-plastic analysis using idealized explicit FEM. A temperature increment is set in magnitude to have a value larger in magnitude than a temperature increment used in a thermal-elastic-plastic analysis using static implicit FEM. Heating is performed for each plurality of blocks according to a heating pattern in which blocks that are not adjacent to one another are simultaneously heated. Each block is heated with a surface heat source having a heat input quantity adjusted with respect to a heat input quantity applied when a moving heat source is used to heat the block.