Cellular scanning strategy for selective laser melting: Generating reliable, optimized scanning paths and processing parameters

Sankhya Mohanty; Jesper Henri Hattel

doi:10.1117/12.2079957

16 March 2015 Cellular scanning strategy for selective laser melting: Generating reliable, optimized scanning paths and processing parameters

Sankhya Mohanty, Jesper Henri Hattel

Author Affiliations +

Proceedings Volume 9353, Laser 3D Manufacturing II; 93530U (2015) https://doi.org/10.1117/12.2079957
Event: SPIE LASE, 2015, San Francisco, California, United States

Abstract

Selective laser melting is yet to become a standardized industrial manufacturing technique. The process continues to suffer from defects such as distortions, residual stresses, localized deformations and warpage caused primarily due to the localized heating, rapid cooling and high temperature gradients that occur during the process. While process monitoring and control of selective laser melting is an active area of research, establishing the reliability and robustness of the process still remains a challenge.

In this paper, a methodology for generating reliable, optimized scanning paths and process parameters for selective laser melting of a standard sample is introduced. The processing of the sample is simulated by sequentially coupling a calibrated 3D pseudo-analytical thermal model with a 3D finite element mechanical model.

The optimized processing parameters are subjected to a Monte Carlo method based uncertainty and reliability analysis. The reliability of the scanning paths are established using cumulative probability distribution functions for process output criteria such as sample density, thermal homogeneity, etc. A customized genetic algorithm is used along with the simulation model to generate optimized cellular scanning strategies and processing parameters, with an objective of reducing thermal asymmetries and mechanical deformations. The optimized scanning strategies are used for selective laser melting of the standard samples, and experimental and numerical results are compared.

Citation Download Citation

Sankhya Mohanty and Jesper Henri Hattel "Cellular scanning strategy for selective laser melting: Generating reliable, optimized scanning paths and processing parameters", Proc. SPIE 9353, Laser 3D Manufacturing II, 93530U (16 March 2015); https://doi.org/10.1117/12.2079957

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