Wang, C., Sun, C. N., Zhang, L., Feih, S., & Wang, P. (2024). Improving component dimensional accuracy in electron beam powder bed fusion by addressing nonlinear deformations with 3D compensation strategies. Virtual and Physical Prototyping, 19(1). https://doi.org/10.1080/17452759.2024.2430319
Abstract:
Electron beam powder bed fusion (EB-PBF) is effective for producing complex geometricalcomponents with minimal residual stress because of elevated powder bed temperatures;however, it faces challenges in achieving dimensional accuracy due to nonlinear shrinkage. Wesystematically investigated the thermal shrinkage behaviour of large-scale EB-PBF componentsand developed 3D nonlinear compensation strategies. A thermal-mechanical model wasdeveloped to simulate residual stress and deformation during printing and cooling, revealingthat nonlinear shrinkage is linked to thermal history, stress distribution, and material properties.The proposed method improved dimensional accuracy, reducing maximum errors from 1.81 mmto 0.16 mm, meeting industrial tolerances for components sized 77 × 48 × 326 mm. Hereafter,we developed a comprehensive digital workflow encompassing topology optimisation andcompensation, validated through a case study on a topology-optimised satellite component.This approach enhances manufacturing precision and significantly reduces trial-and-erroriterations in product design, resulting in substantial time and cost savings.
License type:
Attribution 4.0 International (CC BY 4.0)
Funding Info:
This research / project is supported by the A*STAR - Career Development Fund
Grant Reference no. : C210112043
This research / project is supported by the A*STAR - Manufacturing, Trade, and Connectivity Programmatic Fund
Grant Reference no. : M22L2b0111