DED process parameters optimisation via simulation (C)

As Additive Manufacturing (AM) gains popularity, there is a growing emphasis on refining its processes to fully capitalise on the benefits it offers. Among the various AM techniques used, Directed Energy Deposition (DED) is the most popular, and significant efforts are being made to understand and improve its operational parameters, to improve the efficiency and quality of the final product. This Final Year Project (FYP) aims to investigate the optimal input parameters for a DED process. ANSYS Fluent was used to simulate a DED nozzle model and analyse the convergence point of the powder flow. This FYP also investigates the effect turbulence models have on DED simulations. The focal point height obtained from these simulations, using different turbulence models, will be compared with the experimental results. Comparison between simulation and experimental results suggest that there are significant differences when using different turbulence models. The results obtained show that there is potential for new directions towards further refinement of turbulence modelling for DED processes, which can aid in progressing the understanding of DED processes.Bachelor of Engineering (Mechanical Engineering