Selective laser melting (SLM) is one of the widely used techniques in metallic additive manufacturing, in which high-density laser powder is utilized to selectively melting layers of powders to create geometrically complex parts. Temperature distribution and molten pool geometry directly determine the balling effect, and concentrated balling phenomenon significantly deteriorates surface integrity and mechanical properties of the part. Finite element models have been developed to predict temperature distribution and molten pool geometry, but they were computationally expensive. In this paper, the three-dimensional temperature distributions are predicted by analytical models using point moving heat source and semi-ellipsoidal moving source respectively. The molten pool dimensions under various process conditions are obtained from the three-dimensional temperature predictions and experimentally validated. Ti-6Al-4V alloy is chosen for the investigation. Good agreements between the predictions and the measurements are observed. The presented models are also suitable for other metallic materials in the SLM process.

Different process parameters can alter the temperature during machining. Consequently, selecting process parameters that lead to a desirable cutting temperature would help to increase the tool life, decrease the tensile residual stress, and controls the microstructure evolution of the workpiece. An inverse computational methodology is proposed to design the process parameters for specific cutting temperature. A physics-based analytical model is used to predict the temperature induced by cutting forces. To calculate the temperature induced by the deformation in the shear zone, a moving point heat source approach is used. The shear deformation and chip formation model is implemented to calculate machining forces as functions of process parameters, material properties, and etc. The proposed model uses the analytical model to predict the cutting temperatures and applies a variance-based recursive method to guide the inverse analysis. In order to achieve the cutting process parameters, an iterative gradient search is used to adaptively approach the specific temperature by the optimization of process parameters such that an inverse reasoning can be achieved. Experimental data are used to illustrate the implementation and validate the viability of the computational methodology.

Residual stress (RS) is the most challenging problem in metal additive manufacturing (AM) since the build-up of high tensile RS may influence the fatigue life, corrosion resistance, crack initiation, and failure of the additively manufactured components. While tensile RS is inherent in all the AM processes, fast and accurate prediction of stress state within the part is extremely valuable and would result in optimization of the process parameters in achieving a desired RS and control of the build process. This paper proposes a physics-based analytical model to rapidly and accurately predict the RS within the additively manufactured part. In this model, a transient moving point heat source (HS) is utilized to determine the temperature field. Due to the high temperature gradient within the proximity of the melt pool area, material experience high thermal stress. Thermal stress is calculated by combining three sources of stresses known as stresses due to the body forces, normal tension, and hydrostatic stress in a homogeneous semi-infinite medium. The thermal stress determines the RS state within the part. Consequently, by taking the thermal stress history as an input, both the in-plane and out of plane RS distributions are found from incremental plasticity and kinematic hardening behavior of the metal by considering volume conservation in plastic deformation in coupling with the equilibrium and compatibility conditions. In this modeling, material properties are temperature-sensitive since the steep temperature gradient varies the properties significantly. Moreover, the energy needed for the solid-state phase transition is reflected by modifying the specific heat employing the latent heat of fusion. Furthermore, the multi-layer and multi-scan aspects of metal AM are considered by including the temperature history from previous layers and scans. Results from the analytical RS model presented excellent agreement with XRD measurements employed to determine the RS in the Ti-6Al-4V specimens.

Residual stress (RS) is the most challenging problem in metal additive manufacturing (AM) since the build-up of high tensile RS may influence the fatigue life, corrosion resistance, crack initiation, and failure of the additively manufactured components. While tensile RS is inherent in all the AM processes, fast and accurate prediction of stress state within the part is extremely valuable and would result in optimization of the process parameters in achieving a desired RS and control of the build process. This paper proposes a physics-based analytical model to rapidly and accurately predict the RS within the additively manufactured part. In this model, a transient moving point heat source (HS) is utilized to determine the temperature field. Due to the high temperature gradient within the proximity of the melt pool area, material experience high thermal stress. Thermal stress is calculated by combining three sources of stresses known as stresses due to the body forces, normal tension, and hydrostatic stress in a homogeneous semi-infinite medium. The thermal stress determines the RS state within the part. Consequently, by taking the thermal stress history as an input, both the in-plane and out of plane RS distributions are found from incremental plasticity and kinematic hardening behavior of the metal by considering volume conservation in plastic deformation in coupling with the equilibrium and compatibility conditions. In this modeling, material properties are temperature-sensitive since the steep temperature gradient varies the properties significantly. Moreover, the energy needed for the solid-state phase transition is reflected by modifying the specific heat employing the latent heat of fusion. Furthermore, the multi-layer and multi-scan aspects of metal AM are considered by including the temperature history from previous layers and scans. Results from the analytical RS model presented excellent agreement with XRD measurements employed to determine the RS in the Ti-6Al-4V specimens.

Temperature field is an essential attribute of metal additive manufacturing in view of its bearings on the prediction, control, and optimization of residual stress, part distortion, fatigue, balling effect, etc. This work provides an analytical physics-based approach to investigate the effect of scan strategy parameters including time delay between two irradiations and hatching space on thermal material properties and melt pool geometry. This approach is performed through the analysis of the distribution of material properties and temperature profile in three-dimensional space. The moving point heat source approach is used to predict the temperature field. To predict the temperature field during the additive manufacturing process some important phenomena are considered. 1) Due to the high magnitude of temperature in the presence of the laser, the temperature gradient is usually high which has a crucial influence on thermal material properties. Consequently, the thermal material properties of stainless steel grade 316L are considered to be temperature-dependent. 2) Due to the repeated heating and cooling, part usually undergoes several melting and solidification cycles. This physical phenomenon is considered by modifying the heat capacity using the latent heat of melting. 3) The multi-layer aspect of metal AM process is considered by incorporating the temperature history from the previous layer since the interaction of the successive layers has an impact on heat transfer mechanisms. 4) Effect of heat affected zone on thermal material properties is considered by the superposition of material properties in regions where the temperature fields of two consecutive irradiations have an overlap since the consecutive irradiations change the behavior of the material properties. The goals are to 1) investigate the effects of temperature-sensitive material properties and constant material properties on the temperature field. 2) Study the behavior of thermal material properties under different scan strategies. 3) Study the importance of considering the effect of heat affected zone on thermal material through the prediction of melt pool geometry. 4) Investigate the effect of hatching space on melt pool geometry. This work is purely employed physics-based analytical models to predict the behavior of material properties and temperature field under different process conditions, and no finite element modeling is used.

Selective laser melting is an emerging Additive Manufacturing (AM) technology for metals. Intricate three-dimensional parts can be generated from the powder bed by selectively melting the desired location of the powders. The process is repeated for each layer until the part is built. The necessary heat is provided by a laser. Temperature magnitude and history during SLM directly determine the molten pool dimensions, thermal stress, residual stress, balling effect, and dimensional accuracy. Laser-matter interaction is a crucial physical phenomenon in the SLM process. In this paper, five different heat source models are introduced to predict the three-dimensional temperature field analytically. These models are known as steady state moving point heat source, transient moving point heat source, semi-elliptical moving heat source, double elliptical moving heat source, and uniform moving heat source. The analytical temperature model for all of the heat source models are solved using three-dimensional differential equation of heat conduction with different approaches. The Steady state and transient moving heat source are solved using separation of variables approach. However, the rest of models are solved by employing the Green’s functions. Due to the high magnitude of the temperature in the presence of the laser, the temperature gradient is usually high which has a substantial impact on thermal material properties. Consequently, the temperature field is predicted by considering the temperature sensitivity thermal material properties. Moreover, due to the repeated heating and cooling, the part usually undergoes several melting and solidification cycles, this physical phenomenon is considered by modifying the heat capacity using latent heat of melting. Furthermore, the multi-layer aspect of metal AM process is considered by incorporating the temperature history from the previous layer since the interaction of the layers have an impact on heat transfer mechanisms. The proposed temperature field models based on different heat source approaches are validated using experimental measurement of melt pool geometry from independent experimentations. The detailed explanation of the comparison of models is also provided. Moreover, the effect of process parameters on the balling effect is also discussed.

In the process of metal cutting, the anti-wear performance of the tool determines the life of the tool and affects the surface quality of the workpiece. The finite element simulation method can directly show the tool wear state and morphology, but due to the limitations of the simulation time and complex boundary conditions, it has not been commonly used in tool life prediction. Based on this, a tool wear model was established on the platform of a finite element simulation software for the cutting process of titanium alloy TC4 by end milling. The key technique is to embed different types of tool wear models into the finite element model in combination with the consequent development technology. The effectiveness of the tool wear model is validated by comparing the experimental results with the simulation results. At the same time, in order to quickly predict the tool life, an empirical prediction formula of tool wear was established, and the change course of tool wear under time change was obtained.

Force reduction is one of the most important benefit of applying ultrasonic vibration on milling. However, most of studies so far are limited to experimental investigation. In the current study, an analytical predictive model on cutting forces in ultrasonic vibration-assisted milling is proposed. The three types of tool-workpiece criteria are considered based on the instantaneous position and velocity of tool center. Type I criterion indicates that there is no contact if the instantaneous velocity is opposite to tool rotation direction. Type II criterion checks whether the vibration displacement is larger than the instantaneous uncut chip thickness. Type III criterion considers the overlaps between current and previous tool paths due to vibration. If none of these criteria is satisfied, milling forces are nonzero. Then the calculation is performed by transforming milling and tool geometry configuration to orthogonal cutting at each instant. The orthogonal cutting forces are predicted through the exhaustive search of shear angle and calculation of shear flow stress on tool-chip interface. The axial force is then calculated based on tool geometry, and the milling forces in feed, cutting, and axial directions are calculated after coordinate transformation. The proposed predictive force model in ultrasonic vibration-assisted milling is validated through comparison to experimental measurements on Aluminum alloy 2A12. The predicted values are able to match the measured milling forces with high accuracy of average difference of 13.6% in feed direction and 13.8% in cutting direction.

In laser-assisted milling, higher temperature in shear zone softens the material potentially resulting in a shift of mean residual stress, which significantly affects the damage tolerance and fatigue performance of product. In order to guide the selection of laser and cutting parameters based on the preferred mean residual stress, inverse analysis is conducted by predicting residual stress based on guessed process parameters, which is defined as the forward problem, and applying iterative gradient search to find process parameters for next iteration, which is defined as the inverse problem. An analytical inverse analysis is therefore proposed for the mean residual stress in laser-assisted milling. The forward problem is solved by analytical prediction of mean residual stress after laser-assisted milling. The residual stress profile is predicted through the calculation of thermal stress, by treating laser beam as heat source, and plastic stress by first assuming pure elastic stress in loading process, then obtaining true stress with kinematic hardening followed by the stress relaxation. The variance-based recursive method is applied to solve inverse problem by updating process parameters to match the measured mean residual stress. Three cutting parameters including depth of cut, feed per tooth, and cutting speed, and two laser parameters including laser-tool distance and laser power, are updated with respected to the minimization of resulting residual stress and measurement in each iteration. Experimental measurements are referred on the laser-assisted milling of Ti-6Al-4V grade 5 and ELI. The percentage difference between experiments and predictions is less than 5% for both materials, and the selection is completed within 50 loops.