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Finite Element Simulation of the Fused Deposition Modelling Process

In this paper, the commercial finite element software package Abaqus is used to simulate the FDM process. A Mobius arm part is used to illustrate the simulation procedure and a sequentially coupled thermo-mechanical analysis is performed. The heat transfer analysis calculates the temperature history which is mapped onto and used to predict residual stress and potential part distortion in the subsequent structural analysis. The tool path patterns dictate how material is progressively added to the part during the build and directly influence the accumulation of residual stresses within the part. Independent tool path events are characterized using event series data such as time, location and bead cross-sectional area.

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Finite Element Simulation of the Fused Deposition Modelling Process
Phase Transformations in Metals during Additive Manufacturing Processes

The impetus of additive manufacturing (AM) technology in the last few years is significant. However, in many cases the reliability of the technology leads to parts that suffer from manufacturing defects and hence subpar strength and fatigue life when compared to parts manufactured with conventional technologies. Sustained experimentation is often required and computer simulations, like in many other fields before, are sought to provide significant insight into the process such that progress in raising the quality of AM parts can be achieved. This paper presents a sequential thermals-stress modelling approach of additive manufacturing processes of titanium alloy Ti-6Al-4V parts leveraging a new physics-based framework in a general-purpose finite element code (Abaqus).

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Phase Transformations in Metals during Additive Manufacturing Processes

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