PROCESS AND MATERIAL MODELLING OF METAL ADDITIVE

MANUFACTURING
Deepak Soman,1 Asim Tewari,2 Sushil Mishra3
1
Indian Institute of Technology, Mumbai-400076, India. E-mail: deepak_soman@iitb.ac.in
2
Indian Institute of Technology, Mumbai-400076, India. E-mail: asim.tewari@iitb.ac.in
3
Indian Institute of Technology, Mumbai-400076, India. E-mail: sushil.mishra@iitb.ac.in

ABSTRACT

Metal additive manufacturing (AM) is an emerging technology for the creation

of complex metal geometries with minimal processing. Among its flaws, the
generation of residual stresses is of particular importance as it degrades
performance and distorts geometry. In this study, a numerical model of the AM
process is developed to study the effect of process parameters and material
properties on residual stress and inelastic strain distribution. The model solves a
coupled finite element heat transfer and solid mechanics problem for an
additively manufactured Archimedean spiral track. The model accounts for the
key features of the AM process, such as a moving heat source, metal addition
and solidification. A comparison is made between results obtained for various
combinations of laser power and scan velocity and track spacing.

Keywords: Modelling, Residual stress, Additive, Manufacturing.