Xiaoyu Zhang^1,2, Huizhong Zeng², Shaohui Zhang², Yan Zhang^3,*, Mi Xiao⁴, Liping Liu², Hao Zhou^2,*, Hongyou Chai², Liang Gao⁴

CMES-Computer Modeling in Engineering & Sciences, Vol.138, No.1, pp. 201-220, 2024, DOI:10.32604/cmes.2023.029389

Abstract Lightweight thin-walled structures with lattice infill are widely desired in satellite for their high stiffness-to-weight ratio and superior buckling strength resulting from the sandwich effect. Such structures can be fabricated by metallic additive manufacturing technique, such as selective laser melting (SLM). However, the maximum dimensions of actual structures are usually in a sub-meter scale, which results in restrictions on their appliance in aerospace and other fields. In this work, a meter-scale thin-walled structure with lattice infill is designed for the fuel tank supporting component of the satellite by integrating a self-supporting lattice into the thickness optimization of the thin-wall. The… More >

Kang-Hyun Lee¹, Gun Jin Yun^1,2,*

CMC-Computers, Materials & Continua, Vol.66, No.1, pp. 87-112, 2021, DOI:10.32604/cmc.2020.012688

Abstract Re-melting process has been utilized to mitigate the residual stress level in the selective laser melting (SLM) process in recent years. However, the complex consolidation mechanism of powder and the different material behavior after the first laser melting hinder the direct implementation of the re-melting process. In this work, the effects of re-melting on the temperature and residual stress evolution in the SLM process are investigated using a thermo-mechanically coupled finite element model. The degree of consolidation is incorporated in the energy balance equation based on the thermodynamically-consistent phase-field approach. The drastic change of material properties due to the variation… More >

Jianrui Zhang^1,2, Min Chi¹, Bo Qian^1,*, Zhijun Qiu²

CMES-Computer Modeling in Engineering & Sciences, Vol.125, No.1, pp. 77-94, 2020, DOI:10.32604/cmes.2020.010518

Abstract To accurately perform the coupled simulation of temperature field and stress field of complex parts and porous structures under the optimal manufacturing process parameters, three kinds of porous structures with different complexity were designed in this paper. Firstly, ANSYS additive software was used to conduct the stress/deformation simulation of the whole structure under different scanning strategies. Secondly, the optimal scanning strategy for different porous structures was determined, then the experimental preparation was performed, and mechanical properties of compression were tested and studied. The results show that the elastic modulus and yield strength increase with the increase of pole diameter/wall thickness.… More >

Xiaojun Chen¹, Di Wang^1,*, Wenhao Dou¹, Yimeng Wang¹, Yongqiang Yang¹, Jianhua Wang², Jie Chen¹

CMES-Computer Modeling in Engineering & Sciences, Vol.124, No.3, pp. 1099-1117, 2020, DOI:10.32604/cmes.2020.09619

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 >

Donghua Dai^1,2, Dongdong Gu^1,2,*, Qing Ge^1,2, Chenglong Ma^1,2, Xinyu Shi^1,2, Han Zhang^1,2

CMES-Computer Modeling in Engineering & Sciences, Vol.124, No.3, pp. 1085-1098, 2020, DOI:10.32604/cmes.2020.010927

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 >

Zhiqiang Wang¹, Xuede Wang¹, Xin Zhou^1,*, Guangzhao Ye², Xing Cheng^1,3, Peiyu Zhang¹

CMES-Computer Modeling in Engineering & Sciences, Vol.124, No.1, pp. 243-263, 2020, DOI:10.32604/cmes.2020.09934

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 >

Di Wang¹, Guangzhao Ye¹, Jingming Mai², Xiaomin Chen¹, Yongqiang Yang^1,*, Yang Li^1,*, Xiaojun Chen¹, Jie Chen¹

CMES-Computer Modeling in Engineering & Sciences, Vol.123, No.3, pp. 1061-1077, 2020, DOI:10.32604/cmes.2020.09842

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 >

Xinglong Wang^1,2, Cheng Wang^1,2, Xin Zhou^1,*, Mingkang Zhang³, Peiyu Zhang¹, Lei Wang²

CMES-Computer Modeling in Engineering & Sciences, Vol.123, No.2, pp. 495-508, 2020, DOI:10.32604/cmes.2020.09778

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 >