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• W2594842457 abstract "Selective laser melting (SLM) is an additive manufacturing (AM) technique that is used for metallic products. These products are built in a layer by layer manner by means of selectively melting and hence fusing a layer of metal powder with a laser scanning along a predefined path. The SLM process is able to create products with complex geometries, high accuracy, and within a single manufacturing step. Although SLM presents a number of advantages, the thermal loading causing residual stresses and distortions is an important issue in SLM products. Residual stresses may lead to a limited load resistance and cracks leading to impaired toughness. Distortions may cause the SLM product to be manufactured outside of design tolerances. Therefore, for an SLM product it is essential to accurately predict residual stresses and distortion in the design phase. In literature a great variety of modelling techniques are proposed to capture the physics of the process. Two most widely used approaches to model the process are the melting pool scale and the layer by layer modelling approach. The latter is a computationally efficient way of modelling but does not contain complex process history whereas the former is computationally expensive but can capture the effects of scanning strategy and other process parameters. In this thesis a novel modelling approach is presented which combines the advantages of modelling at the layer scale and the melting pool scale. The general idea is that, the source of strain, giving rise to residual stresses during the SLM process for a given scanning strategy is reconstructed from a detailed simulation and mapped onto a layer. In order to do this the eigenstrain reconstruction method (ERM) is utilised. In this method an equivalent strain source is reconstructed for a residual stress field. The reconstructed equivalent strain source or eigenstrain can be used as a building block to describe the strain source for an entire layer or product. By defining the strain source for an entire product, the residual stresses in the product can be predicted directly. The novelty of the work presented in this thesis lies in the way the residual stress field is predicted. In literature the residual stress field caused by the SLM process is directly mapped to a layer or product. In this approach it is not the stress field that is mapped to the layer or product but the strain source. The advantage of this idea is that the resulting residual stress fields fromthe strain source are continuous in the SLMproduct. Although the ERM is widely used to model 1D and 2D residual stress fields for welding and peening processes, so far no fully 3D ERM has been implemented. In real SLM products the residual stress fields are always multi-axial. Therefore, it is necessary to extend ERMto 3D which is capable of dealing with the multidimensionality of the residual stress fields. One of the requirements of ERMis the input of a reference residual stress field. Therefore an expensive numerical reference model is developed which includes the effect of scanning strategy on the residual stress and warpage of a SLMproduct. The ERM model developed in this thesis is validated by reconstructing the residual stress fields for three geometries; a line, layer and ten layer geometry. The residual stress distributions calculated by the eigenstrain are compared with the results of the expensive numerical reference model. In this model the scanning strategy is incorporated by a point by point modelling approach. The performance of ERM is evaluated by calculating the corresponding residual stress field error between reference and ERM results, which lies within 0.5-4%. It is concluded that the ERMis a suitablemethod to reconstruct equivalent strain sources or eigenstrains for predicting 3D residual stress fields caused by the SLMprocess. The contribution to the field consists of an expansion of ERMto three dimensions and a hybrid model for the SLMprocess which combines the computational efficiency of the global approach with the detail of the local approach." @default.
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• W2594842457 date "2016-01-01" @default.
• W2594842457 modified "2023-09-27" @default.
• W2594842457 title "Eigenstrain reconstruction of residual stresses induced by selective laser melting" @default.
• W2594842457 hasPublicationYear "2016" @default.
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