Simulation Of Additive Manufacturing Using Meshfree Methods

This book provides a detailed instruction to virtually reproduce the processes of Additive Manufacturing on a computer. First, all mathematical equations needed to model these processes are presented. Due to their flexibility, meshfree methods represent optimal computational solution schemes to simulate Additive Manufacturing processes. On the other hand, these methods usually do not guarantee an accurate solution. For this reason, this monograph is dedicated in detail to the necessary criteria for computational solution schemes to provide accurate results. Several meshfree methods are examined with respect to these conditions. Two different 3D printing techniques are presented in detail. The results obtained from the simulation are investigated and compared with experimental data. This work is addressed to both scientists and professionals working in the field of development who are interested to learn the secrets behind meshfree methods or get into the modeling of Additive Manufacturing.

Within the last decade, several industrialized countries have stressed the importance of advanced manufacturing to their economies. Many of these plans have highlighted the development of additive manufacturing techniques, such as 3D printing which, as of 2018, are still in their infancy. The objective is to develop superior products, produced at lower overall operational costs. For these goals to be realized, a deep understanding of the essential ingredients comprising the materials involved in additive manufacturing is needed. The combination of rigorous material modeling theories, coupled with the dramatic increase of computational power can potentially play a significant role in the analysis, control, and design of many emerging additive manufacturing processes. Specialized materials and the precise design of their properties are key factors in the processes. Specifically, particle-functionalized materials play a central role in this field, in three main regimes: (1) to enhance overall filament-based material properties, by embedding particles within a binder, which is then passed through a heating element and the deposited onto a surface, (2) to “functionalize” inks by adding particles to freely flowing solvents forming a mixture, which is then deposited onto a surface and (3) to directly deposit particles, as dry powders, onto surfaces and then to heat them with a laser, e-beam or other external source, in order to fuse them into place. The goal of these processes is primarily to build surface structures which are extremely difficult to construct using classical manufacturing methods. The objective of this monograph is introduce the readers to basic techniques which can allow them to rapidly develop and analyze particulate-based materials needed in such additive manufacturing processes. This monograph is broken into two main parts: “Continuum Method” (CM) approaches and “Discrete Element Method” (DEM) approaches. The materials associated with methods (1) and (2) are closely related types of continua (particles embedded in a continuous binder) and are treated using continuum approaches. The materials in method (3), which are of a discrete particulate character, are analyzed using discrete element methods.

Laser-Based Additive Manufacturing Explore laser-based additive manufacturing processes via multi-scale modeling and computer simulation In Laser-Based Additive Manufacturing: Modeling, Simulation, and Experiments, a distinguished team of researchers delivers an incisive framework for understanding materials processing using laser-based additive manufacturing (LAM). The book describes the use of computational modeling and simulation to explore and describe the LAM technique, to improve the compositional, phase, and microstructural evolution of the material, and to enhance the mechanical, chemical, and functional properties of the manufactured components. The accomplished authors combine a comprehensive overview of multi-scale modeling and simulation with experimental and practical observations, offering a systematic review of laser-material interactions in advanced LAM processes. They also describe the real-world applications of LAM, including component processing and surface functionalization. In addition to explorations of residual stresses, three-dimensional defects, and surface physical texture in LAM, readers will also find: A thorough introduction to additive manufacturing (AM), including the advantages of AM over conventional manufacturing and the challenges involved with using the technology A comprehensive exploration of computation materials science, including length- and time-scales in materials modeling and the current state of computational modeling in LAM Practical discussions of laser-material interaction in LAM, including the conversion of light energy to heat, modes of heat dissipation, and the dynamics of the melt-pool In-depth examinations of the microstructural and mechanical aspects of LAM integrated with modeling Perfect for materials scientists, mechanical engineers, and physicists, Laser-Based Additive Manufacturing: Modeling, Simulation, and Experiments is perfect for anyone seeking an insightful treatment of this cutting-edge technology in the areas of alloys, ceramics, and composites.

This book comprehensively introduces readers to Digital Twins, from the basic concepts, core technologies and technical architecture, to application scenarios and other aspects. Readers will gain a profound understanding of the emerging discipline of Digital Twins. Covering the latest and cutting-edge application technologies of Digital Twins in various fields, the book offers practitioners concrete problem-solving strategies. At the same time, it helps those working in Digital Twins-related fields to deepen their understanding of the industry and enhance their professional knowledge and skills. Given its scope, the book can also be used as teaching material or a reference book for teachers and students of product design, industrial design, design management, design marketing and related disciplines at colleges and universities. Covering a variety of groundbreaking Digital Twins technologies, it can also provide new directions for researchers.

Provides thorough coverage of essential concepts and state-of-the-art developments in the field Meshfree and Particle Methods is the first book of its kind to combine comprehensive, up-to-date information on the fundamental theories and applications of meshfree methods with systematic guidance on practical coding implementation. Broad in scope and content, this unique volume provides readers with the knowledge necessary to perform research and solve challenging problems in nearly all fields of science and engineering using meshfree computational techniques. The authors provide detailed descriptions of essential issues in meshfree methods, as well as specific techniques to address them, while discussing a wide range of subjects and use cases. Topics include approximations in meshfree methods, nonlinear meshfree methods, essential boundary condition enforcement, quadrature in meshfree methods, strong form collocation methods, and more. Throughout the book, topics are integrated with descriptions of computer implementation and an open-source code (with a dedicated chapter for users) to illustrate the connection between the formulations discussed in the text and their real-world implementation and application. This authoritative resource: Explains the fundamentals of meshfree methods, their constructions, and their unique capabilities as compared to traditional methods Features an overview of the open-source meshfree code RKPM2D, including code and numerical examples Describes all the variational concepts required to solve scientific and engineering problems using meshfree methods such as Nitsche’s method and the Lagrange multiplier method Includes comprehensive reviews of essential boundary condition enforcement, quadrature in meshfree methods, and nonlinear aspects of meshfree analysis Discusses other Galerkin meshfree methods, strong form meshfree methods, and their comparisons Meshfree and Particle Methods: Fundamentals and Applications is the perfect introduction to meshfree methods for upper-level students in advanced numerical analysis courses, and is an invaluable reference for professionals in mechanical, aerospace, civil, and structural engineering, and related fields, who want to understand and apply these concepts directly, or effectively use commercial and other production meshfree and particle codes in their work.

Meshfree and Particle Methods Provides thorough coverage of essential concepts and state-of-the-art developments in the field Meshfree and Particle Methods is the first book of its kind to combine comprehensive, up-to-date information on the fundamental theories and applications of meshfree methods with systematic guidance on practical coding implementation. Broad in scope and content, this unique volume provides readers with the knowledge necessary to perform research and solve challenging problems in nearly all fields of science and engineering using meshfree computational techniques. The authors provide detailed descriptions of essential issues in meshfree methods, as well as specific techniques to address them, while discussing a wide range of subjects and use cases. Topics include approximations in meshfree methods, nonlinear meshfree methods, essential boundary condition enforcement, quadrature in meshfree methods, strong form collocation methods, and more. Throughout the book, topics are integrated with descriptions of computer implementation and an open-source code (with a dedicated chapter for users) to illustrate the connection between the formulations discussed in the text and their real-world implementation and application. This authoritative resource: Explains the fundamentals of meshfree methods, their constructions, and their unique capabilities as compared to traditional methods Features an overview of the open-source meshfree code RKPM2D, including code and numerical examples Describes all the variational concepts required to solve scientific and engineering problems using meshfree methods such as Nitsche’s method and the Lagrange multiplier method Includes comprehensive reviews of essential boundary condition enforcement, quadrature in meshfree methods, and nonlinear aspects of meshfree analysis Discusses other Galerkin meshfree methods, strong form meshfree methods, and their comparisons Meshfree and Particle Methods: Fundamentals and Applications is the perfect introduction to meshfree methods for upper-level students in advanced numerical analysis courses, and is an invaluable reference for professionals in mechanical, aerospace, civil, and structural engineering, and related fields, who want to understand and apply these concepts directly, or effectively use commercial and other production meshfree and particle codes in their work.

Manufacturing industries strive to improve the quality and reliability of their products, while simultaneously reducing production costs. To do this, modernized work tools must be produced; this will enable a reduction in the duration of the product development cycle, optimization of product development procedures, and ultimately improvement in the productivity of design and manufacturing phases. Numerical simulations of forming processes are used to this end, and in this book various methods and models for forming processes (including stamping, hydroforming and additive manufacturing) are presented. The theoretical and numerical advances of these processes involving large deformation mechanics on the basis of large transformations are explored, in addition to the various techniques for optimization and calculation of reliability. The advances and techniques within this book will be of interest to professional engineers in the automotive, aerospace, defence and other industries, as well as graduates and undergraduates in these fields.

This book shares insights on post-processing techniques adopted to achieve precision-grade surfaces of additive manufactured metals including material characterization techniques and the identified material properties. Post-processes are discussed from support structure removal and heat treatment to the material removal processes including hybrid manufacturing. Also discussed are case studies on unique applications of additive manufactured metals as an exemplary of the considerations taken during post-processing design and selection. Addresses the critical aspect of post-processing for metal additive manufacturing Provides systematic introduction of pertinent materials Demonstrates post-process technique selection with the enhanced understanding of material characterization methods and evaluation Includes in-depth validation of ultra-precision machining technology Reviews precision fabrication of industrial-grade titanium alloys, steels, and aluminium alloys, with additive manufacturing technology The book is aimed at researchers, professionals, and graduate students in advanced manufacturing, additive manufacturing, machining, and materials processing.