Related Experiment Video
Updated: Aug 4, 2025
11:11
Experimental Methods for Investigation of Shape Memory Based Elastocaloric Cooling Processes and Model Validation
Published on: May 2, 2016
11.1K
Modeling and Simulation of Additively Manufactured Cylindrical Component Using Combined Thermomechanical and Inherent
Thoufeili Taufek1,2, Yupiter H P Manurung1,2, Mohd Shahriman Adenan1,2
1Smart Manufacturing Research Institute (SMRI), Universiti Teknologi MARA (UiTM) Shah Alam, Shah Alam, Malaysia.
3D Printing and Additive Manufacturing
|March 31, 2023
Summary
This study introduces a combined thermomechanical-inherent strain method (TMM-ISM) to predict distortion in 3D printed parts. The TMM-ISM significantly reduces simulation time compared to traditional thermomechanical methods (TMM) while maintaining accuracy.
Area of Science:
- Materials Science and Engineering
- Computational Mechanics
- Additive Manufacturing
Background:
- Additive manufacturing (AM) processes like selective laser melting (SLM) often result in component distortion.
- Accurate prediction of distortion is crucial for ensuring the quality and performance of AM parts.
- Traditional simulation methods, such as thermomechanical analysis (TMM), can be computationally intensive and time-consuming.
Purpose of the Study:
- To apply and verify a combined thermomechanical-inherent strain method (TMM-ISM) for predicting distortion in additively manufactured components.
- To compare the accuracy and computational efficiency of the TMM-ISM against the traditional TMM approach.
- To validate simulation results with experimental data for a vertical cylinder manufactured via SLM.
Main Methods:
- A virtual calibration test was performed using TMM to obtain inherent strain values.
- An optimization algorithm (Nelder-Mead method in MATLAB) was developed to determine inherent strain values by minimizing distortion error.
- Manufacturing process simulation was conducted using the inherent strain method (ISM), followed by comparison with full TMM simulations and experimental results.
Main Results:
- The TMM-ISM achieved good agreement with experimental results for slit distortion, with an error of 9.5%.
- The traditional TMM also showed good agreement with experimental results, with a lower error of 3.5%.
- The computational time for TMM-ISM (63 minutes) was significantly reduced compared to TMM (129 minutes) for a solid cylindrical component.
Conclusions:
- The combined TMM-ISM is a viable and efficient alternative for predicting distortion in additively manufactured components.
- TMM-ISM offers a substantial reduction in computational time, making it suitable for complex analyses.
- This method can help overcome the limitations of time-consuming and costly calibration procedures in AM.
Related Concept Videos
01:12Temperature Dependent Deformation
176
In a nonhomogeneous rod made up of steel and brass, restrained at both ends and subjected to a temperature change, several steps are involved in calculating the stress and compressive load. Due to the problem's static indeterminacy, one end support is disconnected, allowing the rod to experience the temperature change freely. Next, an unknown force is applied at the free end, triggering deformations in the rod's steel and brass portions. These deformations are then calculated and added...
176
01:10Residual Stresses in Circular Shafts
208
In materials that exhibit elastic and plastic behavior, known as elastoplastic materials, residual stresses can accumulate when these materials experience plastic deformation. This deformation arises from either high levels of shearing stress or significant strains. Residual stresses are internal stresses that persist within a material after removing the external force causing deformation. This phenomenon is demonstrated when observing the behavior of a shaft under torque; notably, the...
208
01:20Plastic Deformation in Circular Shafts
212
When materials are subjected to forces that surpass their yield strength, they undergo a process known as plastic deformation. This results in a permanent alteration or strain in their structure. This concept can be specifically applied to circular shafts, where the deformation leads to a change in its shape. The precise evaluation of this plastic deformation requires understanding the stress distribution within the circular shaft, which is achieved by calculating the maximum shearing stress in...
212
01:14Bending of Curved Members - Strain Analysis
166
The mechanics of deformation in curved members, such as beams or arches, under bending moments, involve complex responses. When such a member, symmetric about the y-axis and shaped like a segment of a circle centered at point C, is subjected to equal and opposite forces, its curvature and surface lengths change significantly. This alteration results in the shift of the curvature's center from C to C', indicating a tighter curve.
The important part of bending analysis for such a member...
The important part of bending analysis for such a member...
166
01:15Design of Transmission Shafts - Stress Analysis
432
Designing a transmission shaft requires a thorough understanding of the stresses induced by bending moments and torques, especially in systems where power is transferred through gears. These forces create force-couple systems at the centers of the shaft's cross-sections, leading to both transverse and torsional loading. Although shearing stresses from transverse loads are typically smaller than those from torques and are often overlooked, the significant normal stresses from these loads...
432
01:29Three-Dimensional Analysis of Strain
263
Three-dimensional strain analysis is crucial for understanding how materials deform under stress, particularly in elastic, homogeneous materials. This method employs principal stress axes to simplify complex stress states into more understandable forms. Subjected to stress, a small cubic element within a material either expands or contracts along these axes, transforming into a rectangular parallelepiped. This transformation effectively illustrates the material's deformation. The principal...
263