Simulation Applications for Additive Manufacturing

Compared to traditional manufacturing processes, Additive Manufacturing produces parts by adding material in layers. Each layer is a thin cross-section of the part derived from the original CAD data. Modeling and simulation of AM process can provide guidance to machine users to optimize their existing machines and build layouts, predict the part performance, and produce parts with desired quality. Validation of modeling and simulation tools makes standardized manufacturing processes possible. The development of simulation for predicting the effects of changes in process parameters on mechanical properties, residual stress/strain, crystal structure, and other micro & macro features of components made using metal-based AM techniques has been developed at the University of Louisville (UofL) and is being commercialized by 3DSIM, LLC. In order to test this structure, a series of benchmarking and validation experiments applicable to industry were designed. The outcomes of these studies will be discussed in this presentation