Table of Content

Design & simulation in Additive Manufacturing

Submission Deadline: 31 March 2020 (closed)

Guest Editors

Prof. Yongqiang Yang, South China University of Technology, China
Prof. Shoufeng Yang, KU Leuven, Belgium.
Prof. Li Yang, University of Louisville, USA.
Prof. Hao Wang, National University of Singapore, Singapore
Prof. Di Wang, South China University of Technology, China
Prof. Yingjun Wang, South China University of Technology, China

Summary

Additive Manufacturing (AM) is a process of joining materials to make objects from 3D model data, usually layer upon layer. There are barriers and challenges bordering the development of AM. First, there are many complex multi-physics phenomena during most AM processes, such as molten pool dynamic problem and spatter problem. Second, the comprehensive interaction effect among factors like materials, the support of component, heat transfer and operation parameters, result in manufacturing defects. Third, the freeform design based on AM usually is applied in multi-phase or strict conditions that are difficult to measure or analyze. The newly CAD design methods and numerical simulation, as well as other computational approaches are key to solve these problems and push the development of AM.

With the rapid growth of researches in additive manufacturing, we initiate this special issue to highlight the recent developments with simulation and computational approaches in AM. This special issue seeks original manuscripts to investigate the theory, design, optimization, simulation and process of AM. Papers which deal with multi-physics problems, as well as those which deal with the interfaces of mechanics, chemistry, and biology, are particularly encouraged. Various length scales (quantum, nano, micro, meso, and macro), and various time scales (femtoseconds to hours) are of interest. Both experimental and modeling submissions are encouraged.
Potential topics included but are not limited to: 
(1) Design, modeling, simulation and analysis based on AM.
(2) Simulation of microstructure stability and evolution during or after the AM process.
(3) Simulation of multi-physics problems in AM, such as molten pool dynamic problem, spatter problem, ejection and injection problems.
(4) AM process enhancements and numerical simulation, such as thermal deformation, crack. 
(5) Microstructure and property relationship of the AM components.
(6) Biomedical, energy and other novel applications of AM.
(7) Multi-materials, multi-technology(hybrid) processes and machines enhancements with simulation analysis.
(8) Other related topics…


Keywords

Additive Manufacturing; Computational Physics; Numerical Simulation; Computational Fluid Dynamics; Mechanical Property; Topology Optimization.

Published Papers


  • Open Access

    EDITORIAL

    Introduction to the Special Issue on Design and Simulation in Additive Manufacturing

    Di Wang, Yongqiang Yang, Yingjun Wang, Li Yang, Hao Wang, Shoufeng Yang
    CMES-Computer Modeling in Engineering & Sciences, Vol.126, No.1, pp. 1-4, 2021, DOI:10.32604/cmes.2021.015180
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract This article has no abstract. More >

  • Open Access

    ARTICLE

    Mesoscopic-Scale Numerical Investigation Including the Inuence of Process Parameters on LPBF Multi-Layer Multi-Path Formation

    Liu Cao
    CMES-Computer Modeling in Engineering & Sciences, Vol.126, No.1, pp. 5-23, 2021, DOI:10.32604/cmes.2021.014693
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract As a typical laser additive manufacturing technology, laser powder bed fusion (LPBF) has achieved demonstration applications in aerospace, biomedical and other fields. However, how to select process parameters quickly and reasonably is still the main concern of LPBF production. In order to quantitatively analyze the inuence of different process parameters (laser power, scanning speed, hatch space and layer thickness) on the LPBF process, the multi-layer and multi-path forming process of LPBF was predicted based on the open-source discrete element method framework Yade and the open-source finite volume method framework OpenFOAM. Based on the design of experiments method, a four-factor three-level… More >

  • Open Access

    ARTICLE

    Inverse Construction Methods of Heterogeneous NURBS Object Based on Additive Manufacturing

    Ting Zang, Dongbin Zhu, Guowang Mu
    CMES-Computer Modeling in Engineering & Sciences, Vol.125, No.2, pp. 597-610, 2020, DOI:10.32604/cmes.2020.09965
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract According to the requirement of heterogeneous object modeling in additive manufacturing (AM), the Non-Uniform Rational B-Spline (NURBS) method has been applied to the digital representation of heterogeneous object in this paper. By putting forward the NURBS material data structure and establishing heterogeneous NURBS object model, the accurate mathematical unified representation of analytical and free heterogeneous objects have been realized. With the inverse modeling of heterogeneous NURBS objects, the geometry and material distribution can be better designed to meet the actual needs. Radical Basis Function (RBF) method based on global surface reconstruction and the tensor product surface interpolation method are combined… More >

  • Open Access

    ARTICLE

    Thermodynamics of Molten Pool Predicted by Computational Fluid Dynamics in Selective Laser Melting of Ti6Al4V: Surface Morphology Evolution and Densification Behavior

    Donghua Dai, Dongdong Gu, Qing Ge, Chenglong Ma, Xinyu Shi, Han Zhang
    CMES-Computer Modeling in Engineering & Sciences, Vol.124, No.3, pp. 1085-1098, 2020, DOI:10.32604/cmes.2020.010927
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract The three-dimensional physical model of the randomly packed powder material irradiated by the laser beam was established, taking into account the transformation of the material phase, the melt spreading and the interaction of the free surface of the molten pool and the recoiling pressure caused by the material evaporation during the selective laser melting. Influence of the processing parameters on the thermal behavior, the material evaporation, the surface morphology and the densification behavior in the connection region of the molten pool and the substrate was studied. It was shown that the powder material underwent the transformation from the partial melting… More >

  • Open Access

    ARTICLE

    Design and Manufacture of Bionic Porous Titanium Alloy Spinal Implant Based on Selective Laser Melting (SLM)

    Xiaojun Chen, Di Wang, Wenhao Dou, Yimeng Wang, Yongqiang Yang, Jianhua Wang, Jie Chen
    CMES-Computer Modeling in Engineering & Sciences, Vol.124, No.3, pp. 1099-1117, 2020, DOI:10.32604/cmes.2020.09619
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract In order to meet the clinical requirements of spine surgery, this paper proposed the exploratory research of computer-aided design and selective laser melting (SLM) fabrication of a bionic porous titanium spine implant. The structural design of the spinal implant is based on CT scanning data to ensure correct matching, and the mechanical properties of the implant are verified by simulation analysis and laser selective melting experiment. The surface roughness of the spinal implant manufactured by SLM without post-processing is Ra 15 μm, and the implant is precisely jointed with the photosensitive resin model of the upper and lower spine. The… More >

  • Open Access

    ARTICLE

    A New Finite Element Model with Manufactured Error for Additive Manufacturing

    Zhaohui Xia, Zhihao He, Qifu Wang, Yingjun Wang
    CMES-Computer Modeling in Engineering & Sciences, Vol.124, No.2, pp. 703-720, 2020, DOI:10.32604/cmes.2020.010368
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract Additive manufacturing (AM), adding materials layer by layer, can be used to produce objects of almost any shape or geometry. However, AM techniques cannot accurately build parts with large overhangs, especially for the large features close to horizontal, hanging over the void. The overhangs will make the manufactured model deviate from the design model, which will result in the performance of the manufactured model that cannot satisfy the design requirements. In this paper, we will propose a new finite element (FE) analysis model that includes the manufacturing errors by mimicking the AM layer by layer construction process. In such FE… More >

  • Open Access

    ARTICLE

    Numerical Simulation of Multi-Layer Penetration Process of Binder Droplet in 3DP Technique

    Xiangyu Gao, Weidong Yang, Hongxuan Xian, Xiyuan Tu, Yuanyuang Wang
    CMES-Computer Modeling in Engineering & Sciences, Vol.124, No.1, pp. 227-241, 2020, DOI:10.32604/cmes.2020.09923
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract This paper studies the binder droplet injection process in the 3DP technique. The mathematical model of the binder penetration process for multi-nozzle and multi-layer in 3DP technique is established, by using the conservation Level set method. According to the two-dimensional plane model of three-dimensional spatial structure of sand bed, the construction method of an equivalent cylindrical mapping infiltration model is proposed to represent the porosity of the model in the two-dimensional plane, which is exactly the same as that in the three-dimensional space, as well as closer to the arrangement of the three-dimensional space, and to realize the differentiation between… More >

  • Open Access

    ARTICLE

    Investigation into Spatter Particles and Their Effect on the Formation Quality During Selective Laser Melting Processes

    Zhiqiang Wang, Xuede Wang, Xin Zhou, Guangzhao Ye, Xing Cheng, Peiyu Zhang
    CMES-Computer Modeling in Engineering & Sciences, Vol.124, No.1, pp. 243-263, 2020, DOI:10.32604/cmes.2020.09934
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract During the selective laser melting process, a high-energy laser beam acts on the powder, a molten pool is rapidly generated and the characteristic parameters are constantly changing. Among them, temperature is one of the important parameters in the forming process. Due to the generation of splash particles, there will be defects in the microstructure, which will seriously affect the formation quality of the prepared parts. Therefore, it is necessary to study the relationships between the splash behavior, molten pool characteristics and product quality. The finite element simulation of the transient temperature field was performed by ANSYS software. Time-series images at… More >

  • Open Access

    ARTICLE

    Novel Micromixer with Complex 3D-Shape Inner Units: Design, Simulation and Additive Manufacturing

    Di Wang, Guangzhao Ye, Jingming Mai, Xiaomin Chen, Yongqiang Yang, Yang Li, Xiaojun Chen, Jie Chen
    CMES-Computer Modeling in Engineering & Sciences, Vol.123, No.3, pp. 1061-1077, 2020, DOI:10.32604/cmes.2020.09842
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract In this paper, a novel micromixer with complex 3D-shape inner units was put forward and fabricated by metal Additive Manufacturing (AM). The design of the micromixer combined the constraints of selective laser melting technology and the factors to improve mixing efficiency. Villermaux-Dushman reaction system and Compute Fluid Design (CFD) simulation were conducted to investigate the performance and the mechanism of this novel micromixer to improve mixing efficiency. The research found that the best mixing efficiency of this novel micromixer could be gained when the inner units divided fluid into five pieces with a uniform volume. Compared with a conventional micromixer… More >

  • Open Access

    ARTICLE

    Innovative Design and Additive Manufacturing of Regenerative Cooling Thermal Protection System Based on the Triply Periodic Minimal Surface Porous Structure

    Xinglong Wang, Cheng Wang, Xin Zhou, Mingkang Zhang, Peiyu Zhang, Lei Wang
    CMES-Computer Modeling in Engineering & Sciences, Vol.123, No.2, pp. 495-508, 2020, DOI:10.32604/cmes.2020.09778
    (This article belongs to this Special Issue: Design & simulation in Additive Manufacturing)
    Abstract The new regenerative cooling thermal protection system exhibits the multifunctional characteristics of load-carrying and heat exchange cooling, which are fundamental for the lightweight design and thermal protection of hypersonic vehicles. Triply periodic minimal surface (TPMS) is especially suitable for the structural design of the internal cavity of regenerative cooling structures owing to its excellent structural characteristics. In this study, test pieces were manufactured using Ti6Al4V lightweight material. We designed three types of porous test pieces, and the interior was filled with a TPMS lattice (Gyroid, Primitive, I-WP) with a porosity of 30%. All porous test pieces were manufactured via selective… More >

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