Parametric Study of Metal 3D Printing Process Using Finite Element Simulation

2019 ◽  
Author(s):  
Kshitiz Khanna ◽  
Raymond K. Yee
Keyword(s):  
Finite Element ◽  
3D Printing ◽  
Process Parameters ◽  
Heat Sink ◽  
Parametric Study ◽  
Base Plate ◽  
Plate Temperature ◽  
Initial Layer ◽  
Desirable Outcome ◽  
Metal 3D Printing

Abstract Metal additive manufacturing (AM), also known as metal 3D printing, is a challenging process to be controlled for desirable outcome due to its many process parameters. Residual stresses or deformations may occur in an AM manufactured part because of rapid heating and cooling cycles in the layers. The effect of process-controlled parameters in laser powder bed fusion (L-PBF) on deformations of a manufactured part has not been well examined and reported only sparely in literature. The objectives of this paper are: to study deformation behavior of a L-PBF printed part using finite element method, to perform parametric study of process input variables by changing few selected process parameters in the simulations, and to attempt identifying optimal values within the studied range of selected parameters to minimize part distortion. In this study, the material used for the heat sink finite element model was Inconel 718 which is commonly found in AM manufactured parts. ANSYS finite element program was employed to simulate a heat sink fabrication. The finished dimensions of the heat sink model were 12 mm in height, 26 mm in width, and 26 mm in depth. Thermal-mechanical sequential coupling approach was employed to simulate layer-by-layer built up process. The resulting deformations was evaluated by varying laser travel speed, base plate temperature, and initial layer angle. The maximum deformation (distortion) was observed at the corners of the heat sink model upon release from the base plate and found to be approximately 0.115 mm. Based on this study, the relative optimal simulation results for minimum distortion for selected parameters were 600 °K base plate temperature, 600 mm/sec speed of laser, and 0° initial layer angle. These results can be served as foundation for further study of varying other L-PBF process parameters.

Parametric Study of a Simply Supported Composite Plate Using Finite Element Method

2014 ◽  
Vol 4 (4) ◽  
pp. 26-33
Author(s):  
P.Deepak Kumar ◽  
◽  
Ishan Sharma ◽  
P.R. Maiti ◽  
◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Parametric Study ◽  
Composite Plate ◽  
Simply Supported ◽  
Element Method

A Fracture Mechanics Based Parametric Study of the Copper-to-Copper Direct Thermo-Compression Bonded Interface Using Finite Element Method

2013 ◽  
Author(s):  
Ah-Young Park ◽  
Satish Chaparala ◽  
Seungbae Park
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Parametric Study ◽  
Initial Crack ◽  
Bonding Interface ◽  
Interface Condition ◽  
Large Temperature ◽  
Bonded Interface ◽  
The Impact ◽  
Element Method

Through-silicon via (TSV) technology is expected to overcome the limitations of I/O density and helps in enhancing system performance of conventional flip chip packages. One of the challenges for producing reliable TSV packages is the stacking and joining of thin wafers or dies. In the case of the conventional solder interconnections, many reliability issues arise at the interface between solder and copper bump. As an alternative solution, Cu-Cu direct thermo-compression bonding (CuDB) is a possible option to enable three-dimension (3D) package integration. CuDB has several advantages over the solder based micro bump joining, such as reduction in soldering process steps, enabling higher interconnect density, enhanced thermal conductivity and decreased concerns about intermetallic compounds (IMC) formation. Critical issue of CuDB is bonding interface condition. After the bonding process, Cu-Cu direct bonding interface is obtained. However, several researchers have reported small voids at the bonded interface. These defects can act as an initial crack which may lead to eventual fracture of the interface. The fracture could happen due to the thermal expansion coefficient (CTE) mismatch between the substrate and the chip during the postbonding process, board level reflow or thermal cycling with large temperature changes. In this study, a quantitative assessment of the energy release rate has been made at the CuDB interface during temperature change finite element method (FEM). A parametric study is conducted to analyze the impact of the initial crack location and the material properties of surrounding materials. Finally, design recommendations are provided to minimize the probability of interfacial delamination in CuDB.

Finite Element Analysis of the Distributed Vibration Absorbers for Structural Noise Control

2005 ◽  
Author(s):  
Ashwini Gautam ◽  
Chris Fuller ◽  
James Carneal
Keyword(s):  
Finite Element ◽  
Numerical Model ◽  
Base Plate ◽  
Element Model ◽  
Fe Model ◽  
Vibration Absorbers ◽  
Element Analysis ◽  
Poroelastic Media ◽  
Hexahedral Elements ◽  
Component Models

This work presents an extensive analysis of the properties of distributed vibration absorbers (DVAs) and their effectiveness in controlling the sound radiation from the base structure. The DVA acts as a distributed mass absorber consisting of a thin metal sheet covering a layer of acoustic foam (porous media) that behaves like a distributed spring-mass-damper system. To assess the effectiveness of these DVAs in controlling the vibration of the base structures (plate) a detailed finite elements model has been developed for the DVA and base plate structure. The foam was modeled as a poroelastic media using 8 node hexahedral elements. The structural (plate) domain was modeled using 16 degree of freedom plate elements. Each of the finite element models have been validated by comparing the numerical results with the available analytical and experimental results. These component models were combined to model the DVA. Preliminary experiments conducted on the DVAs have shown an excellent agreement between the results obtained from the numerical model of the DVA and from the experiments. The component models and the DVA model were then combined into a larger FE model comprised of a base plate with the DVA treatment on its surface. The results from the simulation of this numerical model have shown that there has been a significant reduction in the vibration levels of the base plate due to DVA treatment on it. It has been shown from this work that the inclusion of the DVAs on the base plate reduces their vibration response and therefore the radiated noise. Moreover, the detailed development of the finite element model for the foam has provided us with the capability to analyze the physics behind the behavior of the distributed vibration absorbers (DVAs) and to develop more optimized designs for the same.

scholarly journals A Computational Study of the Shear Behavior of Reinforced Concrete Beams Affected from Alkali–Silica Reactivity Damage

Materials ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3346
Author(s):  
Bora Gencturk ◽  
Hadi Aryan ◽  
Mohammad Hanifehzadeh ◽  
Clotilde Chambreuil ◽  
Jianqiang Wei
Keyword(s):  
Finite Element ◽  
Reinforced Concrete ◽  
Parametric Study ◽  
Computational Study ◽  
Element Model ◽  
Shear Behavior ◽  
Shear Capacity ◽  
Reinforced Concrete Beams ◽  
Alkali Silica Reactivity ◽  
Concrete Mechanical Properties

In this study, an investigation of the shear behavior of full-scale reinforced concrete (RC) beams affected from alkali–silica reactivity damage is presented. A detailed finite element model (FEM) was developed and validated with data obtained from the experiments using several metrics, including a force–deformation curve, rebar strains, and crack maps and width. The validated FEM was used in a parametric study to investigate the potential impact of alkali–silica reactivity (ASR) degradation on the shear capacity of the beam. Degradations of concrete mechanical properties were correlated with ASR expansion using material test data and implemented in the FEM for different expansions. The finite element (FE) analysis provided a better understanding of the failure mechanism of ASR-affected RC beam and degradation in the capacity as a function of the ASR expansion. The parametric study using the FEM showed 6%, 19%, and 25% reduction in the shear capacity of the beam, respectively, affected from 0.2%, 0.4%, and 0.6% of ASR-induced expansion.

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