DMLS Process Modelling & Validation

N. N’Dri, H.-W. Mindt, B. Shula, M. Megahed, A. Peralta, P. Kantzos and J. Neumann, DMLS Process Modelling & Validation, TMS 2015 144th Annual Meeting & Exhibition, March 15-19, 2015, Orlando, FL. Proceedings ISBN 978-1-119-08241-5, pp. 389-396, 2015.

This paper discusses the modeling challenges related to additive manufacturing in general and DMLS (Direct Metal Laser Sintering) in particular. A seamless coupling of length scales allowing detailed analysis of the melt pool, laser track, material deposition and resulting residual stresses is presented.

The modelling components are verified separately and the complete modeling process is validated against experimental measurements. Comparison of numerical predictions and experimental measurements show good agreement. Finally, as a practical demonstration of the modelling platform applicability to improved work piece quality, the numerical optimization of deposition tracks to reduce in build residual stresses is demonstrated.