1-16. High-throughput whole-process modeling of additive manufacturing of material materials

Moubin Liu*，Zekun Wang
College of Engineering, Peking University (mbliu@pku.edu.cn)

Abstract: Modeling and simulation play a key role in additive manufacturing (AM) through improving yields, shortening R&D cycles, and predicting and correcting anomalies, and most importantly saving AM production costs. However, computational algorithms and computer modeling techniques for AM are still in the infancy stage, as the whole-process of AM involves multi-scale, multi-phase, and multi-physics with different algorithms and software. Moreover, in order to optimize material properties and processing parameters, high-throughput simulations with enormous data are necessary. 

         In this work, with the support of the National Key Research Project (Grant No.2018YFB0704000), for the first time, we achieved the high-throughput whole-process modeling of powder-scale additive manufacturing of material materials with the coupling of multi-scale algorithms and integration of a number of software. In methodology, we developed a semi-resolved CFD-DEM technique for powder transport or deposit. Together with the interface tracking technique and effective energy source model, the multi-phase powder melting can be modeled. Through linking the powder transport and powder melting, the whole process of AM can then be automatically studied. In applications, the self-controllable code is implemented in high performance computers with multiple cores and multiple tasks to realize high-throughput simulations. As such, high-throughput whole-process simulations are conducted to analyze and optimize material properties and processing parameters, while this can be significantly important in AM.

金属增材制造高通量数值模拟与仿真

刘谋斌*，王泽坤
北京大学工学院

摘要:增材制造(即“3D 打印”)减少了传统制造工艺在优化设计、结构创新及复杂结构制造上 的困难，为下一代工业革命奠定了基础。模拟与仿真可以提升增材制造产能，缩短材料与产品 研发周期，预测及修正产品瑕疵，降低生产成本，在增材制造过程中起着关键的作用。金属增 材制造过程涉及多尺度、多相、多物理场等复杂特征，其数值模拟需要发展与耦合不同尺度的方法，并在海量工艺及材料参数下进行过程仿真。目前国内外在这一方面的工作处于萌芽状态， 仅有非常少量的研究报道，关键算法与模拟平台缺失。

      本文在材料基因工程关键技术与支撑平台国家重点研发计划(2018YFB0704000)的支持下， 通过多尺度材料计算方法的耦合与软件的集成应用，实现了金属增材制造过程铺粉/输粉到熔融 凝固全过程自动流程模拟。在方法上，发展了基于粒子方法-网格方法的耦合技术，结合有效的 能量热源模型与界面追踪及重构技术，再现了增材制造中金属粉末颗粒的运动(输粉、铺粉) 与熔融凝固的全过程，实现粉床上多道乃至多层熔融的数值模拟。在应用方面，结合正在发展的高通量与并行计算技术，可以分析众多工艺参数(激光参数、粉末参数等)下金属增材制造 工艺工程中的复杂物理现象，进行过程仿真与参数优化，研究金属增材制造过程中孔隙、缺陷、 熔池流动、未融合、物质飞溅与熔道剥蚀等关键而目前基本空白却又至关重要的问题，对发展 增材制造自主可控算法与模拟平台具有重要意义。