Hybrid Modeling of Melt Pool Geometry in Additive Manufacturing Using Neural Networks

2021 ◽  
Author(s):  
Kevontrez Jones ◽  
Zhuo Yang ◽  
Ho Yeung ◽  
Paul Witherell ◽  
Yan Lu
Keyword(s):  
Neural Networks ◽  
Finite Element ◽  
Additive Manufacturing ◽  
Real Time ◽  
Hybrid Model ◽  
Computational Models ◽  
Single Layer ◽  
Element Model ◽  
Additive Process ◽  
Melt Pool

Abstract Laser powder-bed fusion is an additive manufacturing (AM) process that offers exciting advantages for the fabrication of metallic parts compared to traditional techniques, such as the ability to create complex geometries with less material waste. However, the intricacy of the additive process and extreme cyclic heating and cooling leads to material defects and variations in mechanical properties; this often results in unpredictable and even inferior performance of additively manufactured materials. Key indicators for the potential performance of a fabricated part are the geometry and temperature of the melt pool during the building process, due to its impact upon the underlining microstructure. Computational models, such as those based on the finite element method, of the AM process can be used to elucidate and predict the effects of various process parameters on the melt pool, according to physical principles. However, these physics-based models tend to be too computationally expensive for real-time process control. Hence, in this work, a hybrid model utilizing neural networks is proposed and demonstrated to be an accurate and efficient alternative for predicting melt pool geometries in AM, which provides a unified description of the melting conditions. The results of both a physics-based finite element model and the hybrid model are compared to real-time experimental measurements of the melt pool during single-layer AM builds using various scanning strategies.

New Hammerstein Modeling and Analysis for Controlling Melt Pool Width in Powder Bed Fusion Additive Manufacturing

2021 ◽  
pp. 1-7
Author(s):  
Dan Wang ◽  
Xinyu Zhao ◽  
Xu Chen
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Process Variations ◽  
Element Model ◽  
Hammerstein Model ◽  
Powder Bed Fusion ◽  
Modeling And Analysis ◽  
Powder Bed ◽  
Melt Pool ◽  
Linearized Model

Abstract Despite the advantages and emerging applications, broader adoption of powder bed fusion (PBF) additive manufacturing is challenged by insufficient reliability and in-process variations. Finite element modeling and control-oriented modeling have been identified fundamental for predicting and engineering part qualities in PBF. This paper first builds a finite element model (FEM) of the thermal fields to look into the convoluted thermal interactions during the PBF process. Using the FEM data, we identify a novel surrogate system model from the laser power to the melt pool width. Linking a linearized model with a memoryless nonlinear submodel, we develop a physics-based Hammerstein model that captures the complex spatiotemporal thermomechanical dynamics. We verify the accuracy of the Hammerstein model using the FEM and prove that the linearized model is only a representation of the Hammerstein model around the equilibrium point. Along the way, we conduct the stability and robustness analyses and formalize the Hammerstein model to facilitate the subsequent control designs.

Finite Element-Based Optimization of Additive Manufacturing Process Using Statistical Modelling and League of Champion Algorithm

2021 ◽  
pp. 215-234
Author(s):  
Anoop Kumar Sood
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Statistical Treatment ◽  
Statistical Modelling ◽  
Element Model ◽  
Linear Constraint ◽  
Melt Pool ◽  
Dimensional Finite Element ◽  
Scan Speed

The study develops a 2D (two-dimensional) finite element model with a Gaussian heat source to simulate powder bed-based laser additive manufacturing process of Ti6Al4V alloy. The modelling approach provides insight into the process by correlating laser power and scan speed with melt pool temperature distribution and size. To tackle the FEA result in optimization environment, statistical approach of data normalization and regression modelling is adopted. Statistical treatment is not only able to deduce the interdependence of various objectives consider but also make the representation of objectives and constraint computationally simple. Adoption of a new stochastic algorithm namely league of a champion algorithm (LCA) together with penalty function approach for non-linear constraint handling reduces the effort required and computational complexity involved in determining the optimum parameter setting.

Theories and Computational Models for Composite Laminates

1994 ◽  
Vol 47 (6) ◽  
pp. 147-169 ◽  
Author(s):  
J. N. Reddy ◽  
D. H. Robbins
Keyword(s):  
Finite Element ◽  
Composite Laminates ◽  
Computational Models ◽  
Single Layer ◽  
Element Model ◽  
Senior Author ◽  
Superposition Method ◽  
Multiple Model ◽  
Solution Accuracy ◽  
Model Approach

A review of equivalent–single–layer and layerwise laminated plate theories and their finite element models is presented. The layerwise theory advanced by the senior author is presented and a variable displacement finite element model and mesh superposition techniques are described. A simultaneous multiple model approach that is based on the variable kinematic theory and the mesh superposition method are also described. The objective of the simultaneous multiple model approach is to match the most appropriate mathematical model with each subregion based on the physical characteristics, applied loading, expected behavior, and level of solution accuracy desired in that subregion. Thus solution economy is maximized without sacrificing the solution accuracy.

On real-time creep damage prediction for steam turbine

2022 ◽  
pp. 014233122110689
Author(s):  
Yongjian Sun ◽  
Bo Xu
Keyword(s):  
Finite Element ◽  
Steam Turbine ◽  
Real Time ◽  
Creep Damage ◽  
Element Model ◽  
Turbine Rotor ◽  
Theoretical Research ◽  
Element Analysis ◽  
Damage Prediction ◽  
Time Calculation

In this paper, in order to solve the calculation problem of creep damage of steam turbine rotor, a real-time calculation method based on finite element model is proposed. The temperature field and stress field of the turbine rotor are calculated using finite element analysis software. The temperature data and stress data of the crucial positions are extracted. The data of temperature, pressure, rotational speed, and stress relating to creep damage calculation are normalized. A real-time creep stress calculation model is established by multiple regression method. After that, the relation between stress and damage function is analyzed and fitted, and creep damage is calculated in real-time. A creep damage real-time calculation system is constructed for practical turbine engineering. Finally, a numerical simulation experiment is designed and carried out to verify the effectiveness of this novel approach. Contributions of present work are that a practical solution for real-time creep damage prediction of steam turbine is supplied. It relates the real-time creep damage prediction to process parameters of steam turbine, and it bridges the gap between the theoretical research works and practical engineering.

Perforation mechanics of UHMWPE soft ballistic sub-laminate and soft ballistic armor pack: A finite element study

2021 ◽  
pp. 089270572110420
Author(s):  
Bazle Z (Gama) Haque ◽  
John W Gillespie
Keyword(s):  
Finite Element ◽  
Single Layer ◽  
Areal Density ◽  
Element Model ◽  
Transverse Impact ◽  
Free Standing ◽  
Uhmwpe Fibers ◽  
Ballistic Limit Velocity ◽  
Definition Of ◽  
First Time

Soft-ballistic sub-laminate (SBSL) made from ultra-high molecular weight polyethylene (UHMWPE) fibers in [0/90] stacking sequence are the building block of a multi-layer soft-ballistic armor pack (SBAP, aka Soft Armor). A systematic study of the perforation dynamics of a single layer SBSL and several multi-layer SBAPs (2, 3, 4, 8, 16, 24, 32 layers) is presented for the first time in the literature. A previously validated finite element model of transverse impact on a single layer is used to study the perforation mechanics of multi-layer SBAPs with friction between individual layers. Following the classical definition of ballistic limit velocity, a minimum perforation velocity has been determined for free-standing single layer SBSL and multi-layer SBAPs. For the multi-layer SBAPs, complete perforations have been identified as progressive perforation of individual layers through the thickness. The minimum perforation velocities of multi-layer SBAPS is linear with the areal density for the eight (8) layer target and thicker. Large deformation behavior and perforation mechanics of the SBAPs is discussed in detail.

scholarly journals Aspects of Uncertainty Analysis for Large Nonlinear Computational Models

2010 ◽  
Vol 24-25 ◽  
pp. 25-41 ◽  
Author(s):  
Keith Worden ◽  
W.E. Becker ◽  
Manuela Battipede ◽  
Cecilia Surace
Keyword(s):  
Finite Element ◽  
Monte Carlo ◽  
Computational Models ◽  
Element Model ◽  
Finite Element Models ◽  
Bayesian Algorithm ◽  
Basic Principles ◽  
Structure Interaction ◽  
Output Uncertainty ◽  
Input Uncertainties

This paper concerns the analysis of how uncertainty propagates through large computational models like finite element models. If a model is expensive to run, a Monte Carlo approach based on sampling over the possible model inputs will not be feasible, because the large number of model runs will be prohibitively expensive. Fortunately, an alternative to Monte Carlo is available in the form of the established Bayesian algorithm discussed here; this algorithm can provide information about uncertainty with many less model runs than Monte Carlo requires. The algorithm also provides information regarding sensitivity to the inputs i.e. the extent to which input uncertainties are responsible for output uncertainty. After describing the basic principles of the Bayesian approach, it is illustrated via two case studies: the first concerns a finite element model of a human heart valve and the second, an airship model incorporating fluid structure interaction.

scholarly journals A Vision-Based Approach for Estimating Contact Forces: Applications to Robot-Assisted Surgery

2005 ◽  
Vol 2 (1) ◽  
pp. 53-60 ◽  
Author(s):  
C. W. Kennedy ◽  
J. P. Desai
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Real Time ◽  
Force Feedback ◽  
Element Model ◽  
Robot Arm ◽  
Robot Assisted ◽  
Interaction Forces ◽  
Fem Model ◽  
Nodal Displacements

The primary goal of this paper is to provide force feedback to the user using vision-based techniques. The approach presented in this paper can be used to provide force feedback to the surgeon for robot-assisted procedures. As proof of concept, we have developed a linear elastic finite element model (FEM) of a rubber membrane whereby the nodal displacements of the membrane points are measured using vision. These nodal displacements are the input into our finite element model. In the first experiment, we track the deformation of the membrane in real-time through stereovision and compare it with the actual deformation computed through forward kinematics of the robot arm. On the basis of accurate deformation estimation through vision, we test the physical model of a membrane developed through finite element techniques. The FEM model accurately reflects the interaction forces on the user console when the interaction forces of the robot arm with the membrane are compared with those experienced by the surgeon on the console through the force feedback device. In the second experiment, the PHANToM haptic interface device is used to control the Mitsubishi PA-10 robot arm and interact with the membrane in real-time. Image data obtained through vision of the deformation of the membrane is used as the displacement input for the FEM model to compute the local interaction forces which are then displayed on the user console for providing force feedback and hence closing the loop.

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