Sebastian Hartmann , Oihane Murua , Jon Iñaki Arrizubieta , Aitzol Lamikiz , Peter Mayr
{"title":"基于多尺度方法的激光去毛刺过程数字孪晶","authors":"Sebastian Hartmann , Oihane Murua , Jon Iñaki Arrizubieta , Aitzol Lamikiz , Peter Mayr","doi":"10.1016/j.simpat.2023.102881","DOIUrl":null,"url":null,"abstract":"<div><p>The ramp-up of new geometries, process parameters, and materials can be enormously time and cost-intensive in Additive Manufacturing. Especially for Laser-Directed Energy Deposition (DED-L), the extreme physical environment at the melt pool results in the need for multiple trial-and-error tests to quantify the process behavior. These tests significantly raise manufacturing expenses. A Digital Twin (DT) of the DED-L process can therefore be of substantial value if the amount of experimental testing is hereby reduced. In the present study, a multiscale DT based on coupling a global and local model has been investigated. The global model simulates the heating of the entire part, whereas the local model represents only a specific region of this global geometry. Using a high-density mesh for the local model enables the simulation of the specific laser-powder interactions and fast-cooling rates typical in DED-L. The results of the global model are used to integrate context awareness about the changing process conditions during the print job into the local model. This process evolvement is impossible to obtain with models of smaller dimensions and is of elemental necessity for accurately simulating multi-clad depositions. The DT was validated on an industrial-grade DED-L machine with in-situ process monitoring capabilities. In all cases, the DT shows a high resemblance with the experimental data and metallographic inspections at a reasonable computational cost.</p></div>","PeriodicalId":49518,"journal":{"name":"Simulation Modelling Practice and Theory","volume":null,"pages":null},"PeriodicalIF":3.5000,"publicationDate":"2023-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1569190X23001582/pdfft?md5=ad3c0950b52ede395620ebdfe04de32b&pid=1-s2.0-S1569190X23001582-main.pdf","citationCount":"0","resultStr":"{\"title\":\"Digital Twin of the laser-DED process based on a multiscale approach\",\"authors\":\"Sebastian Hartmann , Oihane Murua , Jon Iñaki Arrizubieta , Aitzol Lamikiz , Peter Mayr\",\"doi\":\"10.1016/j.simpat.2023.102881\",\"DOIUrl\":null,\"url\":null,\"abstract\":\"<div><p>The ramp-up of new geometries, process parameters, and materials can be enormously time and cost-intensive in Additive Manufacturing. Especially for Laser-Directed Energy Deposition (DED-L), the extreme physical environment at the melt pool results in the need for multiple trial-and-error tests to quantify the process behavior. These tests significantly raise manufacturing expenses. A Digital Twin (DT) of the DED-L process can therefore be of substantial value if the amount of experimental testing is hereby reduced. In the present study, a multiscale DT based on coupling a global and local model has been investigated. The global model simulates the heating of the entire part, whereas the local model represents only a specific region of this global geometry. Using a high-density mesh for the local model enables the simulation of the specific laser-powder interactions and fast-cooling rates typical in DED-L. The results of the global model are used to integrate context awareness about the changing process conditions during the print job into the local model. This process evolvement is impossible to obtain with models of smaller dimensions and is of elemental necessity for accurately simulating multi-clad depositions. The DT was validated on an industrial-grade DED-L machine with in-situ process monitoring capabilities. In all cases, the DT shows a high resemblance with the experimental data and metallographic inspections at a reasonable computational cost.</p></div>\",\"PeriodicalId\":49518,\"journal\":{\"name\":\"Simulation Modelling Practice and Theory\",\"volume\":null,\"pages\":null},\"PeriodicalIF\":3.5000,\"publicationDate\":\"2023-12-22\",\"publicationTypes\":\"Journal Article\",\"fieldsOfStudy\":null,\"isOpenAccess\":false,\"openAccessPdf\":\"https://www.sciencedirect.com/science/article/pii/S1569190X23001582/pdfft?md5=ad3c0950b52ede395620ebdfe04de32b&pid=1-s2.0-S1569190X23001582-main.pdf\",\"citationCount\":\"0\",\"resultStr\":null,\"platform\":\"Semanticscholar\",\"paperid\":null,\"PeriodicalName\":\"Simulation Modelling Practice and Theory\",\"FirstCategoryId\":\"94\",\"ListUrlMain\":\"https://www.sciencedirect.com/science/article/pii/S1569190X23001582\",\"RegionNum\":2,\"RegionCategory\":\"计算机科学\",\"ArticlePicture\":[],\"TitleCN\":null,\"AbstractTextCN\":null,\"PMCID\":null,\"EPubDate\":\"\",\"PubModel\":\"\",\"JCR\":\"Q2\",\"JCRName\":\"COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS\",\"Score\":null,\"Total\":0}","platform":"Semanticscholar","paperid":null,"PeriodicalName":"Simulation Modelling Practice and Theory","FirstCategoryId":"94","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S1569190X23001582","RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS","Score":null,"Total":0}
Digital Twin of the laser-DED process based on a multiscale approach
The ramp-up of new geometries, process parameters, and materials can be enormously time and cost-intensive in Additive Manufacturing. Especially for Laser-Directed Energy Deposition (DED-L), the extreme physical environment at the melt pool results in the need for multiple trial-and-error tests to quantify the process behavior. These tests significantly raise manufacturing expenses. A Digital Twin (DT) of the DED-L process can therefore be of substantial value if the amount of experimental testing is hereby reduced. In the present study, a multiscale DT based on coupling a global and local model has been investigated. The global model simulates the heating of the entire part, whereas the local model represents only a specific region of this global geometry. Using a high-density mesh for the local model enables the simulation of the specific laser-powder interactions and fast-cooling rates typical in DED-L. The results of the global model are used to integrate context awareness about the changing process conditions during the print job into the local model. This process evolvement is impossible to obtain with models of smaller dimensions and is of elemental necessity for accurately simulating multi-clad depositions. The DT was validated on an industrial-grade DED-L machine with in-situ process monitoring capabilities. In all cases, the DT shows a high resemblance with the experimental data and metallographic inspections at a reasonable computational cost.
期刊介绍:
The journal Simulation Modelling Practice and Theory provides a forum for original, high-quality papers dealing with any aspect of systems simulation and modelling.
The journal aims at being a reference and a powerful tool to all those professionally active and/or interested in the methods and applications of simulation. Submitted papers will be peer reviewed and must significantly contribute to modelling and simulation in general or use modelling and simulation in application areas.
Paper submission is solicited on:
• theoretical aspects of modelling and simulation including formal modelling, model-checking, random number generators, sensitivity analysis, variance reduction techniques, experimental design, meta-modelling, methods and algorithms for validation and verification, selection and comparison procedures etc.;
• methodology and application of modelling and simulation in any area, including computer systems, networks, real-time and embedded systems, mobile and intelligent agents, manufacturing and transportation systems, management, engineering, biomedical engineering, economics, ecology and environment, education, transaction handling, etc.;
• simulation languages and environments including those, specific to distributed computing, grid computing, high performance computers or computer networks, etc.;
• distributed and real-time simulation, simulation interoperability;
• tools for high performance computing simulation, including dedicated architectures and parallel computing.