The 3D printing process known as SLM involves the melting of the metal powder, which results in a melt-pool. When this melt-pool solidifies, the solidified metal undergoes cooling and reheating in the presence of air and multiple laser passes for continuous material consolidation. As a result of such thermal cycles, the manufactured part develops permanent thermal deformation and residual stresses. The current work proposes the FEM and AM G-code based numerical strategy to qualitatively analyze the formation of such deformations and stresses at part scale. A multi-physics model was developed by coupling of transient thermal heat equation with non-linear structural solver. To mimic the consolidation of material with laser motion, the finite elements were activated as per the pattern of metal deposition under the influence of AM G-code. A numerical experiment was conducted to virtually manufacture the part with mechanical properties of 15–5PH stainless steel [1]. We found that the thermomechanical FEM model interfaced with the AM G-code translated data helps to evaluate the comparable trends of thermal deformation and residual stress results with already established studies. This demonstrates that with a given set of operational instructions, how the thermal conduction, convection and radiation drive the AM process by thermally loading the deposited material. Furthermore, the AM G-code interfacing facilitated the communication of laser scanning path with numerical FEM solver. We anticipate that such development may enable the manufacturing and simulation engineers to early estimate the possible final deformation of the AM fabricated part. Additionally, the developed strategy may also be the initial step for the physically informed neural networks to optimize the laser scan path for precise manufacturing of the metal parts.

称为 SLM 的 3D 打印过程涉及金属粉末的熔化，从而形成熔池。当该熔池凝固时，凝固的金属会在空气和多次激光通过的情况下进行冷却和再加热，以实现连续的材料固结。由于这种热循环，制造的零件会产生永久热变形和残余应力。目前的工作提出了基于 FEM 和 AM G 代码的数值策略来定性分析这种变形和应力在零件尺度上的形成。通过瞬态热方程与非线性结构求解器的耦合开发了多物理场模型。为了模拟激光运动对材料的固结，在 AM G 代码的影响下，根据金属沉积的模式激活了有限元。进行了数值实验以虚拟制造具有 15–5PH 不锈钢机械性能的零件 [1]。我们发现，与 AM G 代码转换数据接口的热机械 FEM 模型有助于评估热变形和残余应力结果与已建立研究的可比趋势。这表明，通过一组给定的操作指令，热传导、对流和辐射如何通过热加载沉积材料来驱动 AM 过程。此外，AM G 代码接口促进了激光扫描路径与数值 FEM 求解器的通信。我们预计这种开发可能使制造和模拟工程师能够及早估计 AM 制造部件可能的最终变形。此外，