SIM-AM 2023


Physically-based Part-scale Simulation

  • Zaeh, Michael (Technical University of Munich)

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Additive manufacturing has transformed numerous industries by enabling the production of highly complex and customized parts with unprecedented design freedom. However, to fully leverage the potential of additive manufacturing, it is crucial to address the inherent challenges in achieving optimal part quality and process efficiency through simulation. This keynote presentation will explore the landscape of industrially relevant additive manufacturing technologies, shedding light on the latest advancements in the field. Participants will gain insights into diverse additive manufacturing processes, including the powder bed fusion of metals using a laser beam and the wire and arc additive manufacturing. The presentation will showcase state-of-the-art technologies that have pushed the boundaries of additive manufacturing, allowing for the production of high-performance materials, multi-material structures, and intricate geometries. Case studies from industries such as the aerospace and the assembly industry will illustrate the impact of these technologies on various applications. Additionally, the keynote will delve into the challenges associated with the physically-based part-scale simulation, emphasizing the importance of accurate and efficient simulation tools in ensuring predictable and repeatable part quality. The presentation will highlight key areas of concern, such as the melt pool modeling, the residual stress prediction, the distortion control, and the post-processing simulation. It will explore the complexities of simulating additive manufacturing processes at a part-scale, considering factors such as material behavior, thermal dynamics, and microstructural evolution. The keynote will also address the experimental validation, presenting strategies to bridge the gap between the virtual and the physical world.