SIM-AM 2023

IS10 - Physically-based Part-scale Simulation

M. Zaeh (Technical University of Munich)

In recent years, additive manufacturing has proven to be a competitive technology for producing parts with a high degree of design freedom. This technology comprises different generative production methods – each with a specific area of application and unique resulting part characteristics. Predicting these properties through numerical simulations is highly desirable, as this approach allows for a first-time-right production of the parts.

Over the course of this Invited Session (IS), the audience will be given an overview of different additive manufacturing technologies: the Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M), the Wire and Arc Additive Manufacturing (WAAM), and the Binder Jetting (BJ). The process-specific challenges, for example form deviations due to an uneven heat input or shrinkage effects, will be addressed. The participants will be introduced to the various ways of describing the physical cause-effect relationships and the numerical modeling approaches, which are necessary to predict the part qualities during the manufacturing process.

The IS topics can be specified as follows:
  • keynote lecture: overview of industrial relevant additive manufacturing technologies and challenges of the physically-based part-scale simulation
  • invited lecture 1: first-time-right manufacturing using simulations in PBF-LB/M
  • invited lecture 2: form deviation simulation of WAAM parts
  • invited lecture 3: simulation of macroscopic failure during PBF-LB/M
  • invited lecture 4: prediction of the shrinkage of BJ parts during the sintering process

The aim of the IS is to bring together experts from various additive manufacturing domains to enable an exchange on the different process-specific challenges. By this, thematical overlaps can be identified and discussed. Participants with a dedicated research field in a specific additive manufacturing technology get the opportunity to widen their field of view regarding physical modeling techniques and numerical approaches on the part-scale.