A Data Driven Approach to the Online Monitoring of the Additive Manufacturing Process

2021 ◽  
Vol 1161 ◽  
pp. 137-144
Author(s):  
Jonas Holtmann ◽  
Denis Kiefel ◽  
Stefan Neumann ◽  
Rainer Stoessel ◽  
Christian U. Grosse
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Online Monitoring ◽  
Pool Data ◽  
Process Data ◽  
Automated Evaluation ◽  
Melt Pool ◽  
Data Driven Approach ◽  
The Cost ◽  
Melt Pool Characteristics

Process monitoring in additive manufacturing (AM), i.e. in laser powder bed fusion (LPBF) of metal parts, has been identified as the crucial bottleneck in accelerating the AM industrialization process. To reduce the cost and time needed to produce and qualify an AM part, an online monitoring system of the manufacturing process is desirable. While the currently available systems capture a large amount of process data, they still lack the ability to interpret the acquired data adequately. In this work we present the first steps towards an automated evaluation of online monitoring data i.e. melt pool data. It is shown that a well-trained convolutional neural network (CNN) is able to detect artificially induced process deviations on the basis of melt pool characteristics.

Simulation of metallic powder bed additive manufacturing processes with the finite element method: A critical review

2016 ◽  
Vol 231 (1) ◽  
pp. 96-117 ◽  
Author(s):  
Babis Schoinochoritis ◽  
Dimitrios Chantzis ◽  
Konstantinos Salonitis
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Experimental Validation ◽  
Metallic Powder ◽  
Manufacturing Processes ◽  
Powder Bed ◽  
Modeling Methodology ◽  
Melt Pool ◽  
Element Simulation ◽  
Melt Pool Characteristics

This article provides a literature review of finite element simulation studies for metallic powder bed additive manufacturing processes. The various approaches in the numerical modeling of the processes and the selection of materials properties are presented in detail. Simulation results are categorized according to three major findings’ groups (i.e. temperature field, residual stresses and melt pool characteristics). Moreover, the means used for the experimental validation of the simulation findings are described. Looking deeper into the studies reviewed, a number of future directions are identified in the context of transforming simulation into a powerful tool for the industrial application of additive manufacturing. Smart modeling approaches should be developed, materials and their properties should be further characterized and standardized, commercial packages specialized in additive manufacturing simulation have to be developed and simulation needs to become part of the modern digital production chains. Finally, the reviewed studies are organized in a table and characterized according to the process and material studied, the modeling methodology and the experimental validation method used in each of them. The key findings of the reviewed studies are also summarized.

A numerical investigation of thermal property effects on melt pool characteristics in powder-bed electron beam additive manufacturing

2016 ◽  
Vol 232 (9) ◽  
pp. 1615-1627 ◽  
Author(s):  
Bo Cheng ◽  
Kevin Chou
Keyword(s):  
Thermal Conductivity ◽  
Electron Beam ◽  
Thermal Properties ◽  
Additive Manufacturing ◽  
Melting Point ◽  
Thermal Property ◽  
Manufacturing Process ◽  
Powder Bed ◽  
Melt Pool ◽  
Melt Pool Size

Powder-bed electron beam additive manufacturing has the potential to be a cost-effective alternative in producing complex-shaped, custom-designed metal parts using various alloys. Material thermal properties have a rather sophisticated effect on the thermal characteristics such as the melt pool geometry in fabrications, impacting the build part quality. The objective of this study is to achieve a quantitative relationship that can correlate the material thermal properties and the melt pool geometric characteristics in the electron beam additive manufacturing process. The motivation is to understand the interactions of material property effect since testing individual properties is insufficient because of the change of almost all thermal properties when switching from one to the other material. In this research, a full-factorial simulation experiment was conducted to include a wide range of the thermal properties and their combinations. A developed finite element thermal model was applied to perform electron beam additive manufacturing process thermal simulations incorporating tested thermal properties. The analysis of variance method was utilized to evaluate different thermal property effects on the simulated melt pool geometry. The major results are summarized as follows. (1) The material melting point is the most dominant factor to the melt pool size. (2) The role of the material thermal conductivity may outweigh the melting point and strongly affects the melt pool size, if the thermal conductivity is very high. (3) Regression equations to correlate the material properties and the melt pool dimension and shape have been established, and the regression-predicted results show a reasonable agreement with the simulation results for tested real-world materials. However, errors still exist for materials with a small melt pool such as copper.

A Sensitivity Analysis Study on the Material Properties and Process Parameters for Selective Laser Melting of Inconel 625

2015 ◽  
Author(s):  
Luis E. Criales ◽  
Yiğit M. Arısoy ◽  
Tuğrul Özel
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Scanning Speed ◽  
Inconel 625 ◽  
Pool Data ◽  
Temperature Profiles ◽  
Laser Melting ◽  
Melt Pool ◽  
Laser Heat Source

A prediction of the 2-D temperature profile and melt pool geometry for Selective Laser Melting (SLM) of Inconel 625 metal powder with a numerically-based approach for solving the heat conduction-diffusion equation was established in this paper. A finite element method solution of the governing equation was developed. A review of the current efforts in numerical modeling for laser-based additive manufacturing is presented. Initially, two-dimensional (2-D) temperature profiles along the scanning (x-direction) and hatch direction (y-direction) are calculated for a moving laser heat source to understand the temperature rise due to heating during SLM. The effects of varying laser power, scanning speed and the powder material’s density are analyzed. Based on the predicted temperature distributions, melt pool geometry, i.e. the locations at which melting of the powder material occurs, is determined. The results are chiefly compared against the published literature on melt pool data. The main goal of this research is to develop a computational tool with which investigation of the importance of various laser, material, and process parameters on the built dimensional quality in laser-based additive manufacturing becomes not only possible but also practical and reproducible.

scholarly journals Additive manufacturing of customized lower limb orthoses – A review

2018 ◽  
Vol 6 (10) ◽  
pp. 141-152
Author(s):  
Jéssica Cristina Dias dos Santos Forte Hensen ◽  
José Aguiomar Foggiatto ◽  
Leandra Ulbricht ◽  
Adriana Maria Wan Stadnik
Keyword(s):  
Additive Manufacturing ◽  
Lower Limb ◽  
Manufacturing Process ◽  
Low Cost ◽  
Scientific Production ◽  
Foot And Ankle ◽  
Research Gaps ◽  
Ankle Foot Orthoses ◽  
The Cost ◽  
3D Digitizing

Additive manufacturing (AM) has been successfully applied in the healthcare and shows potential for modernization of lower limb orthoses manufacturing process. This study aims to analyze the scientific production of AM application in customized lower limb orthoses production (foot and ankle-foot orthoses) to identify possible research gaps. To reach the proposed objective, a systematic literature review was carried out, based on the construction of a bibliographic portfolio, a bibliometric study and on article content analysis. Some study gaps were identified as the cost of the 3D digitalizing and the additive manufacturing process employed. This review will be the basis for the development of research on the application of low cost 3D digitizing and 3D printing technologies in the development of lower limb orthoses.

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