Reduced order modeling via PGD for highly transient thermal evolutions in additive manufacturing

B. Favoretto (1, 2) , C.A. de Hillerin (2) , O. Bettinotti (3) , V. Oancea (4) , Andrea Barbarulo (1)

1 MSSMat - Laboratoire de mécanique des sols, structures et matériaux
2 Dassault Systèmes
3 Dassault Systèmes SIMULIA Corp., Johnston, RI, USA
4 Dassault Systèmes SIMULIA Corp., Johnston, RI, USA

In this paper, a highly performing model order reduction technique called Proper Generalized Decomposition (PGD) is applied to the numerical mod-eling of highly transient non-linear thermal phenomena associated with additive manufacturing (AM) powder bed fabrication (PBF) processes. The manufacturing process allows for unprecedented design freedom but fabricated parts often suffer from lower quality mechanical properties associated with the fast transients and high temperature gradients during the localized melting-solidification process. For this reason, an accurate numerical model for the thermal evolutions is a major necessity. This work focuses on providing a low-cost/high accuracy prediction of the high gradient thermal field occurring in a material under the action of a concentrated moving laser source, while accounting for phase changes, material non-linearities and time and space-dependent boundary conditions. An extensive numerical simulation campaign shows that the use of PGD in this context enables a remarkable reduction in the total number of global matrix inversions (5 times less or better) compared to standard techniques when simulating realistic AM PBF scenarios.

Mots clés: AM Process Simulation; Powder Bed Fabrication; Reduced Order Modeling; Proper Generalized Decomposition

Domaines: Acoustique [physics.class-ph]; Electromagnétisme; Génie mécanique [physics.class-ph]; Mécanique des structures [physics.class-ph]; Vibrations [physics.class-ph]

B. Favoretto, C.A. de Hillerin, O. Bettinotti, V. Oancea, Andrea Barbarulo. Reduced order modeling via PGD for highly transient thermal evolutions in additive manufacturing. Computer Methods in Applied Mechanics and Engineering, 2019, ⟨10.1016/j.cma.2019.02.033⟩. ⟨hal-02062582⟩