Simulation of large-scale additive manufacturing process with a single-phase level set method: a process parameters study

2021 ◽  
Author(s):  
Anh-Duc Le ◽  
Benoît Cosson ◽  
André Chateau Akué Asséko
Keyword(s):  
Additive Manufacturing ◽  
Level Set Method ◽  
Level Set ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Large Scale ◽  
Single Phase

Learning Algorithm Based Modeling and Process Parameters Recommendation System for Binder Jetting Additive Manufacturing Process

2015 ◽  
Author(s):  
Han Chen ◽  
Yaoyao F. Zhao
Keyword(s):  
Additive Manufacturing ◽  
Product Quality ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Process Model ◽  
Recommendation System ◽  
Powder Materials ◽  
Quality Properties ◽  
Binder Jetting ◽  
Printing Time

Binder Jetting (BJ) process is an additive manufacturing process in which powder materials are selectively joined by binder materials. Products can be manufactured layer by layer directly from 3D model data. It is not always easy for manufacturing engineers to choose proper BJ process parameters to meet the end-product quality and fabrication time requirements. This is because the quality properties of the products fabricated by BJ process are significantly affected by the process parameters. And the relationships between process parameters and quality properties are very complicated. In this paper, a process model is developed by Backward Propagation (BP) Neural Network (NN) algorithm based on 16 groups of orthogonal experiment designed by Taguchi Method to express the relationships between 4 key process parameters and 2 key quality properties. Based on the modeling results, an intelligent parameters recommendation system is developed to predict end-product quality properties and printing time, and to recommend process parameters selection based on the process requirements. It can be used as a guideline for selecting the proper printing parameters in BJ to achieve the desired properties and help to reduce the printing time.

Effect of Additive Manufacturing Process Parameters on Turbine Cooling

2019 ◽  
Author(s):  
Jacob C. Snyder ◽  
Karen A. Thole
Keyword(s):  
Heat Transfer ◽  
Additive Manufacturing ◽  
Surface Morphology ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Pressure Loss ◽  
Cooling Performance ◽  
Micro Scale ◽  
Turbine Cooling ◽  
External Cooling

Abstract Turbine cooling is a prime application for additive manufacturing because it enables quick development and implementation of innovative designs optimized for efficient heat removal, especially at the micro-scale. At the micro-scale, however, the surface finish plays a significant role in the heat transfer and pressure loss of any cooling design. Previous research on additively manufactured cooling channels has shown the surface roughness increases both heat transfer and pressure loss to similar levels as highly-engineered turbine cooling schemes. What has not been shown, however, is whether opportunities exist to tailor additively manufactured surfaces through control of the process parameters to further enhance the desired heat transfer and pressure loss characteristics. The results presented in this paper uniquely show the potential of manipulating the parameters within the additive manufacturing process to control the surface morphology, directly influencing turbine cooling. To determine the effect of parameters on cooling performance, coupons were additively manufactured for common internal and external cooling methods using different laser powers, scan speeds, and scanning strategies. Internal and external cooling tests were performed at engine relevant conditions to measure appropriate metrics of performance. Results showed the process parameters have a significant impact on the surface morphology leading to differences in cooling performance. Specifically, internal and external cooling geometries react differently to changes in parameters, highlighting the opportunity to consider process parameters when implementing additive manufacturing for turbine cooling applications.

Simulation of Wave-Body Interaction Using a Single-Phase Level Set Function in the SWENSE Method

2013 ◽  
Author(s):  
Gabriel Reliquet ◽  
Aurélien Drouet ◽  
Pierre-Emmanuel Guillerm ◽  
Erwan Jacquin ◽  
Lionel Gentaz ◽  
...  
Keyword(s):  
Free Surface ◽  
Level Set Method ◽  
Level Set ◽  
Single Phase ◽  
Stokes Equations ◽  
Flow Theory ◽  
Navier Stokes ◽  
Navier Stokes Equations ◽  
Level Set Function ◽  
Set Function

The purpose of this paper is to present combination of the SWENSE (Spectral Wave Explicit Navier-Stokes Equations – [1]) method — an original method to treat fully nonlinear wave-body interactions — and a free surface RANSE (Reynolds Averaged Navier-Stokes Equations) solver using a single-phase Level Set method to capture the interface. The idea is to be able to simulate wave-body interactions under viscous flow theory with strong deformations of the interface (wave breaking in the vicinity of the body, green water on ship decks…), while keeping the advantages of the SWENSE scheme. The SWENSE approach is based on a physical decomposition by combining incident waves described by a nonlinear spectral scheme based on potential flow theory and an adapted Navier-Stokes solver where only the diffracted part of the flow is solved, incident flow parameters seen as forcing terms. In the single-phase Level Set method [2, 3], the air phase is neglected. Thus, only the liquid phase is solved considering a fluid with uniform properties. The location of the free surface is determined by a Level Set function initialised as the signed distance. The accuracy of simulation depends essentially on the pressure scheme used to impose free surface dynamic boundary condition. Comparisons of numerical results with experimental and numerical data for US navy combatant DTMB 5415 in calm water and in head waves are presented.

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