Two-level method part-scale thermal analysis of laser powder bed fusion additive manufacturing

Abstract Numerical simulations of a complete laser powder bed fusion (LPBF) additive manufacturing (AM) process are extremely challenging, or even impossible, to achieve without radical model reduction the complex physical phenomena occurring during process. However, when we adopt reduced with simplified physics, geometries parts usually produced by LPBF AM processes make this kind analysis computationally expensive. In fact, small geometrical features—which might be generated part is designed following principle so-called design for AM, instance, means topology optimization procedures—often require conformal meshes. Immersed boundary methods offer an alternative deal complexity, requiring complicated meshing strategies. The two-level method lies within family numerical and presents flexible tool multi-scale problems. contribution, apply modified version recently introduced part-scale thermal manufactured components. We first validate proposed respect experimental measurements from literature. Then, presented framework simulate topologically optimized structure, showing capability easily features.