Selective laser melting is yet to become a standardized industrial manufacturing technique. The process continues to suffer from defects such as distortions, residual stresses, localized deformations and warpage caused primarily due to the localized heating, rapid cooling and high temperature gradients that occur during the process. While process monitoring and control of selective laser melting is an active area of research, establishing the reliability and robustness of the process still remains a challenge.In this paper, a methodology for generating reliable, optimized scanning paths and process parameters for selective laser melting of a standard sample is introduced. The processing of the sample is simulated by sequentially coupling a calibrated 3D pseudo-analytical thermal model with a 3D finite element mechanical model.The optimized processing parameters are subjected to a Monte Carlo method based uncertainty and reliability analysis. The reliability of the scanning paths are established using cumulative probability distribution functions for process output criteria such as sample density, thermal homogeneity, etc. A customized genetic algorithm is used along with the simulation model to generate optimized cellular scanning strategies and processing parameters, with an objective of reducing thermal asymmetries and mechanical deformations. The optimized scanning strategies are used for selective laser melting of the standard samples, and experimental and numerical results are compared.
|Title of host publication||Proceedings of SPIE : Laser 3D Manufacturing II|
|Editors||Henry Helvajian, Alberto Piqué, Martin Wegener, Bo Gu|
|Number of pages||13|
|Publisher||SPIE - International Society for Optical Engineering|
|Publication status||Published - 2015|
|Series||Proceedings of SPIE, the International Society for Optical Engineering|
Bibliographical noteCopyright 2015 Society of Photo Optical Instrumentation Engineers. One print or electronic copy may be made for personal use only. Systematic electronic or print reproduction and distribution, duplication of any material in this paper for a fee or for commercial purposes, or modification of the content of the paper are prohibited.
- Scan strategies
- Optimized scan strategies
- Pseudo-analytical modeling
- Thermo-mechanical analysis
- Reliability estimation
Mohanty, S., & Hattel, J. H. (2015). Cellular scanning strategy for selective laser melting: Generating reliable, optimized scanning paths and processing parameters. In H. Helvajian, A. Piqué, M. Wegener, & B. Gu (Eds.), Proceedings of SPIE: Laser 3D Manufacturing II (Vol. 9353). [93530U] SPIE - International Society for Optical Engineering. Proceedings of SPIE, the International Society for Optical Engineering, Vol.. 9353 https://doi.org/10.1117/12.2079957