Shakeel Dilawar, Ahsan Khan, Asif Ur Rehman, Syed Zahid Husain, S. Jaffery
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This study presents a novel approach combining multiscale modeling and statistical optimization to minimize residual stress in SS316L.\n\nFindings\nOptimal parameters were identified through simulations and validated with experiments, achieving an 8% deviation. This approach significantly reduced printing costs compared to traditional trial-and-error methods. The analysis revealed a non-monotonic relationship between residual stress and energy density, with an initial increase followed by a decrease with increasing hatch spacing and scanning speed (both contributing to lower energy density). Additionally, beam diameter had a minimal impact compared to other energy density parameters.\n\nOriginality/value\nThis work offers a unique framework for optimizing LPBF processes by combining multiscale modeling with statistical techniques. The identified optimal parameters and insights into the individual and combined effects of energy density parameters provide valuable guidance for mitigating residual stress in SS316L, leading to improved part quality and performance.\n","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4000,"publicationDate":"2024-06-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":"{\"title\":\"Breaking the tradeoff: multiscale optimization for lower cost, lower residual stress LPBF of SS316L\",\"authors\":\"Shakeel Dilawar, Ahsan Khan, Asif Ur Rehman, Syed Zahid Husain, S. Jaffery\",\"doi\":\"10.1108/rpj-12-2023-0446\",\"DOIUrl\":null,\"url\":null,\"abstract\":\"Purpose\\nThe purpose of this study was to use bridge curvature method (BCM) to quantify stress, while multiscale modeling with adaptive coarsening predicted distortions based on experimentally validated models. Taguchi method and response surface method were used to optimize process parameters (energy density, hatch spacing, scanning speed and beam diameter).\\n\\nDesign/methodology/approach\\nLaser powder bed fusion (LPBF) offers significant design freedom but suffers from residual stresses due to rapid melting and solidification. This study presents a novel approach combining multiscale modeling and statistical optimization to minimize residual stress in SS316L.\\n\\nFindings\\nOptimal parameters were identified through simulations and validated with experiments, achieving an 8% deviation. This approach significantly reduced printing costs compared to traditional trial-and-error methods. 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The identified optimal parameters and insights into the individual and combined effects of energy density parameters provide valuable guidance for mitigating residual stress in SS316L, leading to improved part quality and performance.\\n\",\"PeriodicalId\":20981,\"journal\":{\"name\":\"Rapid Prototyping Journal\",\"volume\":null,\"pages\":null},\"PeriodicalIF\":3.4000,\"publicationDate\":\"2024-06-11\",\"publicationTypes\":\"Journal Article\",\"fieldsOfStudy\":null,\"isOpenAccess\":false,\"openAccessPdf\":\"\",\"citationCount\":\"0\",\"resultStr\":null,\"platform\":\"Semanticscholar\",\"paperid\":null,\"PeriodicalName\":\"Rapid Prototyping Journal\",\"FirstCategoryId\":\"5\",\"ListUrlMain\":\"https://doi.org/10.1108/rpj-12-2023-0446\",\"RegionNum\":4,\"RegionCategory\":\"工程技术\",\"ArticlePicture\":[],\"TitleCN\":null,\"AbstractTextCN\":null,\"PMCID\":null,\"EPubDate\":\"\",\"PubModel\":\"\",\"JCR\":\"Q1\",\"JCRName\":\"ENGINEERING, MECHANICAL\",\"Score\":null,\"Total\":0}","platform":"Semanticscholar","paperid":null,"PeriodicalName":"Rapid Prototyping Journal","FirstCategoryId":"5","ListUrlMain":"https://doi.org/10.1108/rpj-12-2023-0446","RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MECHANICAL","Score":null,"Total":0}
Breaking the tradeoff: multiscale optimization for lower cost, lower residual stress LPBF of SS316L
Purpose
The purpose of this study was to use bridge curvature method (BCM) to quantify stress, while multiscale modeling with adaptive coarsening predicted distortions based on experimentally validated models. Taguchi method and response surface method were used to optimize process parameters (energy density, hatch spacing, scanning speed and beam diameter).
Design/methodology/approach
Laser powder bed fusion (LPBF) offers significant design freedom but suffers from residual stresses due to rapid melting and solidification. This study presents a novel approach combining multiscale modeling and statistical optimization to minimize residual stress in SS316L.
Findings
Optimal parameters were identified through simulations and validated with experiments, achieving an 8% deviation. This approach significantly reduced printing costs compared to traditional trial-and-error methods. The analysis revealed a non-monotonic relationship between residual stress and energy density, with an initial increase followed by a decrease with increasing hatch spacing and scanning speed (both contributing to lower energy density). Additionally, beam diameter had a minimal impact compared to other energy density parameters.
Originality/value
This work offers a unique framework for optimizing LPBF processes by combining multiscale modeling with statistical techniques. The identified optimal parameters and insights into the individual and combined effects of energy density parameters provide valuable guidance for mitigating residual stress in SS316L, leading to improved part quality and performance.
期刊介绍:
Rapid Prototyping Journal concentrates on development in a manufacturing environment but covers applications in other areas, such as medicine and construction. All papers published in this field are scattered over a wide range of international publications, none of which actually specializes in this particular discipline, this journal is a vital resource for anyone involved in additive manufacturing. It draws together important refereed papers on all aspects of AM from distinguished sources all over the world, to give a truly international perspective on this dynamic and exciting area.
-Benchmarking – certification and qualification in AM-
Mass customisation in AM-
Design for AM-
Materials aspects-
Reviews of processes/applications-
CAD and other software aspects-
Enhancement of existing processes-
Integration with design process-
Management implications-
New AM processes-
Novel applications of AM parts-
AM for tooling-
Medical applications-
Reverse engineering in relation to AM-
Additive & Subtractive hybrid manufacturing-
Industrialisation