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History Reduction by Lumping for Time-Efficient Simulation of Additive Manufacturing

Department of Engineering Sciences and Mathematics, Luleå University of Technology, 97187 Luleå, Sweden
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Metals 2020, 10(1), 58; https://doi.org/10.3390/met10010058
Received: 3 December 2019 / Revised: 17 December 2019 / Accepted: 18 December 2019 / Published: 29 December 2019
(This article belongs to the Special Issue Modeling Metal 3D Printing Processes)
Additive manufacturing is the process by which material is added layer by layer. In most cases, many layers are added, and the passes are lengthy relative to their thicknesses and widths. This makes finite element simulations of the process computationally demanding owing to the short time steps and large number of elements. The classical lumping approach in computational welding mechanics, popular in the 80s, is therefore, of renewed interest and is evaluated in this work. The method of lumping means that welds are merged. This allows fewer time steps and a coarser mesh. It was found that the computation time can be reduced considerably, with retained accuracy for the resulting temperatures and deformations. The residual stresses become, to a certain degree, smaller. The simulations were validated against a directed energy deposition (DED) experiment with alloy 625. View Full-Text
Keywords: finite element; thermo-mechanical analysis; additive manufacturing; alloy 625 finite element; thermo-mechanical analysis; additive manufacturing; alloy 625
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Malmelöv, A.; Lundbäck, A.; Lindgren, L.-E. History Reduction by Lumping for Time-Efficient Simulation of Additive Manufacturing. Metals 2020, 10, 58.

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