Simulation of the Laser Beam Melting Process – Approaches for an Efficient Modelling of the Beam-material Interaction

AbstractCurrently, the main field of application of additive manufacturing processes is shifting from research laboratories to production facilities. Simulation models can foster this transition by providing support in process development and design. This paper introduces approaches to modelling the beam-material interaction in laser beam melting on a level of detail that allows the simulation of the whole build-up process of parts, not only of single laser tracks. Thus both the achievable result accuracy and the needed calculation time are discussed. For this purpose, fundamental correlations to link process characteristics with model parameters are explained. Subsequently, four modelling approaches are analysed. After an introduction of the well-known method of applying a uniform load on a whole layer compound (e. g. [1]), the developed methods are discussed which allow modelling the beam-material interaction on a more detailed level. Thereby, the focus lies on the ability to model load gradients perpendicular to the build direction. This article is completed with a discussion of simulated temperature curves for selected monitoring points using two different modelling approaches