Modeling and Simulation of Metal AM

Abstract

Additive manufacturing with metal components is a complex, and currently cyclic, process due to the physical phenomena that are occurring. These phenomena can be mathematically modeled in order to predict the outcome of a specific aspect of the build. Coupling the mathematical models can then be used to develop a complete simulation, which can produce estimates for a range of characteristics for a part built using additive manufacturing techniques. This chapter will investigate the main models used in the simulation of metal AM. These models will include the modeling of thermal behavior, fluid dynamics, stress, and a selection of other auxiliary models, which are necessary to complete the simulations. For each of the models investigated, the various modeling techniques that have been developed will be presented along with their limitations, validation techniques, and parameters necessary to model the process correctly.