Comparisons of Numerical Modelling of the Selective Laser Melting

Abstract

Selective laser melting (SLM) first developed for rapid prototyping (RP) is now used for rapid manufacturing of parts with inner complex shapes that cannot be made by more conventional routes. For example, production of injection moulds with cooling channels is of special interest. In this paper, a numerical model of SLM process was investigated to simulate the genesis of residual stresses. The proposed numerical modelling is based upon a double meshing with a multi step birth and death technique of manufactured part. The influence of the mesh size is analysed with element as small as the powder layer thickness for 2D and 3D geometries of simple parts. Comparisons between plane stress, plane strain, and 3D analysis are presented in order to propose a simplified approach.