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Title: Dynamic simulation of powder packing structure for powder bed additive manufacturing

Abstract

Here, powder packing structure is a critical parameter of powder bed-based additive manufacturing (AM). Experimental characterization of powder is typically limited to measuring bulk properties, whereas many numerical models of AM powder packing are based on geometrical consideration without accounting for particle-to-particle interactions. In the present paper, the powder packing dynamics is simulated using a discrete element method (DEM)-based model that solves the mechanical contact forces and moments between individual particles. As DEM uses explicit time integration, a main challenge in modeling dynamics of metallic powder packing is the need for extremely fine time increment size (e.g., in the order of 1 ns for a 10-μm-diameter particle). The effect of mass scaling, employed for speeding up the calculation, on the simulation results is examined in a test case of powder particles packed inside a box container. The calculated packing density for two different particle size distributions is validated against independent literature data for laser powder bed AM with AISI 316L stainless steel powder. The sensitivity of key input parameters (e.g., friction coefficient) is further evaluated in this test case. The powder packing model is then applied to a practical situation of binder jet AM involving rolling of multiple layers ofmore » IN718 powder particles onto a powder bed, for which the calculated packing density is also validated with independent literature data.« less

Authors:
ORCiD logo [1]; ORCiD logo [2]; ORCiD logo [3]
  1. Oak Ridge National Lab. (ORNL), Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); The Ohio State Univ., Columbus, OH (United States)
  2. Oak Ridge National Lab. (ORNL), Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  3. The Ohio State Univ., Columbus, OH (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1422379
DOE Contract Number:  
AC05-00OR22725
Resource Type:
Journal Article
Journal Name:
International Journal of Advanced Manufacturing Technology
Additional Journal Information:
Journal Volume: 96; Journal Issue: 1-4; Journal ID: ISSN 0268-3768
Publisher:
Springer
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; Additive manufacturing; Packing density; Discrete element method; Powder bed; Binder jet

Citation Formats

Lee, Y. S., Nandwana, Peeyush, and Zhang, Wei. Dynamic simulation of powder packing structure for powder bed additive manufacturing. United States: N. p., 2018. Web. doi:10.1007/s00170-018-1697-3.
Lee, Y. S., Nandwana, Peeyush, & Zhang, Wei. Dynamic simulation of powder packing structure for powder bed additive manufacturing. United States. doi:10.1007/s00170-018-1697-3.
Lee, Y. S., Nandwana, Peeyush, and Zhang, Wei. Wed . "Dynamic simulation of powder packing structure for powder bed additive manufacturing". United States. doi:10.1007/s00170-018-1697-3.
@article{osti_1422379,
title = {Dynamic simulation of powder packing structure for powder bed additive manufacturing},
author = {Lee, Y. S. and Nandwana, Peeyush and Zhang, Wei},
abstractNote = {Here, powder packing structure is a critical parameter of powder bed-based additive manufacturing (AM). Experimental characterization of powder is typically limited to measuring bulk properties, whereas many numerical models of AM powder packing are based on geometrical consideration without accounting for particle-to-particle interactions. In the present paper, the powder packing dynamics is simulated using a discrete element method (DEM)-based model that solves the mechanical contact forces and moments between individual particles. As DEM uses explicit time integration, a main challenge in modeling dynamics of metallic powder packing is the need for extremely fine time increment size (e.g., in the order of 1 ns for a 10-μm-diameter particle). The effect of mass scaling, employed for speeding up the calculation, on the simulation results is examined in a test case of powder particles packed inside a box container. The calculated packing density for two different particle size distributions is validated against independent literature data for laser powder bed AM with AISI 316L stainless steel powder. The sensitivity of key input parameters (e.g., friction coefficient) is further evaluated in this test case. The powder packing model is then applied to a practical situation of binder jet AM involving rolling of multiple layers of IN718 powder particles onto a powder bed, for which the calculated packing density is also validated with independent literature data.},
doi = {10.1007/s00170-018-1697-3},
journal = {International Journal of Advanced Manufacturing Technology},
issn = {0268-3768},
number = 1-4,
volume = 96,
place = {United States},
year = {2018},
month = {2}
}