Physics-based and phenomenological plasticity models for thermomechanical simulation in laser powder bed fusion additive manufacturing: A comprehensive numerical comparison.
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| Title: | Physics-based and phenomenological plasticity models for thermomechanical simulation in laser powder bed fusion additive manufacturing: A comprehensive numerical comparison. |
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| Authors: | Promoppatum, Patcharapit1 (AUTHOR), Rollett, Anthony D.1,2,3 (AUTHOR) rollett@andrew.cmu.edu |
| Source: | Materials & Design. Jun2021, Vol. 204, pN.PAG-N.PAG. 1p. |
| Subjects: | Materials testing, Material plasticity, Strains & stresses (Mechanics), Strain rate, Powders, Titanium powder, Metal powders |
| Abstract: | The present study investigated the sensitivity of material constitutive models on thermomechanical responses in laser powder bed fusion additive manufacturing of Ti-6Al-4V. Uniform scan strategies with scan lengths of 0.5, 1, and 2 mm were applied so that wide ranges of thermal histories could be generated. The Johnson-Cook (JC) and Mechanical Threshold Stress (MTS) material plasticity models were chosen to capture the influence of strain, strain rate, and temperature. The JC model is a phenomenological model which is known for its easy implementation and excellent agreement with material testing results. On the other hand, the MTS model is a more complex physics-based internal state variable plasticity model that is expected to provide more accurate estimation, particularly for cases involving changes in strain rate and temperature. Numerical results revealed that both JC and MTS models provided a similar stress evolution, however, the plastic strain evolution was more realistic using the MTS model. Moreover, it was found that the maximum strain and the strain rate in the LPBF process are high compared to typical quasi-static testing, i.e., ~ 2% and ~ 4 s−1, respectively. Accordingly, the material models should be calibrated with data obtained under similar deformation conditions. The choice of scan length also strongly affects in-plane stress anisotropy. Ultimately, we show both qualitatively and quantitatively the dependency of mechanical behavior prediction in LPBF on the choice of material models. [Display omitted] • A three-dimensional thermomechanical finite element model was developed to study the influence of material constitutive models on mechanical responses of the laser powder bed fusion additive manufacturing. • The Mechanical Threshold Stress model and two variants of the Johnson-Cook model were employed in the present study • The numerical model captured the strong dependency of residual stress and plastic strain on the choices of material models. • The present study emphasizes the importance of material calibration at similar deformation conditions to those of the laser powder bed fusion process. [ABSTRACT FROM AUTHOR] |
| Copyright of Materials & Design is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
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| Items | – Name: Title Label: Title Group: Ti Data: Physics-based and phenomenological plasticity models for thermomechanical simulation in laser powder bed fusion additive manufacturing: A comprehensive numerical comparison. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Promoppatum%2C+Patcharapit%22">Promoppatum, Patcharapit</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Rollett%2C+Anthony+D%2E%22">Rollett, Anthony D.</searchLink><relatesTo>1,2,3</relatesTo> (AUTHOR)<i> rollett@andrew.cmu.edu</i> – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Materials+%26+Design%22">Materials & Design</searchLink>. Jun2021, Vol. 204, pN.PAG-N.PAG. 1p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Materials+testing%22">Materials testing</searchLink><br /><searchLink fieldCode="DE" term="%22Material+plasticity%22">Material plasticity</searchLink><br /><searchLink fieldCode="DE" term="%22Strains+%26+stresses+%28Mechanics%29%22">Strains & stresses (Mechanics)</searchLink><br /><searchLink fieldCode="DE" term="%22Strain+rate%22">Strain rate</searchLink><br /><searchLink fieldCode="DE" term="%22Powders%22">Powders</searchLink><br /><searchLink fieldCode="DE" term="%22Titanium+powder%22">Titanium powder</searchLink><br /><searchLink fieldCode="DE" term="%22Metal+powders%22">Metal powders</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: The present study investigated the sensitivity of material constitutive models on thermomechanical responses in laser powder bed fusion additive manufacturing of Ti-6Al-4V. Uniform scan strategies with scan lengths of 0.5, 1, and 2 mm were applied so that wide ranges of thermal histories could be generated. The Johnson-Cook (JC) and Mechanical Threshold Stress (MTS) material plasticity models were chosen to capture the influence of strain, strain rate, and temperature. The JC model is a phenomenological model which is known for its easy implementation and excellent agreement with material testing results. On the other hand, the MTS model is a more complex physics-based internal state variable plasticity model that is expected to provide more accurate estimation, particularly for cases involving changes in strain rate and temperature. Numerical results revealed that both JC and MTS models provided a similar stress evolution, however, the plastic strain evolution was more realistic using the MTS model. Moreover, it was found that the maximum strain and the strain rate in the LPBF process are high compared to typical quasi-static testing, i.e., ~ 2% and ~ 4 s−1, respectively. Accordingly, the material models should be calibrated with data obtained under similar deformation conditions. The choice of scan length also strongly affects in-plane stress anisotropy. Ultimately, we show both qualitatively and quantitatively the dependency of mechanical behavior prediction in LPBF on the choice of material models. [Display omitted] • A three-dimensional thermomechanical finite element model was developed to study the influence of material constitutive models on mechanical responses of the laser powder bed fusion additive manufacturing. • The Mechanical Threshold Stress model and two variants of the Johnson-Cook model were employed in the present study • The numerical model captured the strong dependency of residual stress and plastic strain on the choices of material models. • The present study emphasizes the importance of material calibration at similar deformation conditions to those of the laser powder bed fusion process. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Materials & Design is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1016/j.matdes.2021.109658 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 1 StartPage: N.PAG Subjects: – SubjectFull: Materials testing Type: general – SubjectFull: Material plasticity Type: general – SubjectFull: Strains & stresses (Mechanics) Type: general – SubjectFull: Strain rate Type: general – SubjectFull: Powders Type: general – SubjectFull: Titanium powder Type: general – SubjectFull: Metal powders Type: general Titles: – TitleFull: Physics-based and phenomenological plasticity models for thermomechanical simulation in laser powder bed fusion additive manufacturing: A comprehensive numerical comparison. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Promoppatum, Patcharapit – PersonEntity: Name: NameFull: Rollett, Anthony D. IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 06 Text: Jun2021 Type: published Y: 2021 Identifiers: – Type: issn-print Value: 02641275 Numbering: – Type: volume Value: 204 Titles: – TitleFull: Materials & Design Type: main |
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