PSI - Issue 42

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2019) 000 – 000

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 42 (2022) 299–306

© 2022 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the 23 European Conference on Fracture – ECF23 Abstract Selective Laser Melting (SLM) is an Additive Manufacturing (AM) process aimed for the fabrication of complex metallic parts. Due to the inherent to the process rapid thermal cycles and the developed high temperature gradients, residual stresses are f ormed which result to part distortion and may lead to preliminary failure during its building. Current thermomechanical modelling methods of the SLM process aim at the prediction of residual stress and strain fields in an efficient manner. Meshing schemes such as uniform or adaptive cartesian and layered tetrahedral meshing have been utilized in thermomechanic al modelling but their accuracy has not been evaluated yet. The present study quantitively assess the meshing strategies in the simulation of SLM process with the focus placed on the characteristics of layered tetrahedral meshing. Although it is shown both meshing strategies lead to accurate results for a relatively small element size, layered tetrahedral meshing strategy can achieve convergence with relative coarse mesh and better discretization of curvature regions. © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of 23 European Conference on Fracture - ECF23 Keywords: selective laser melting; finite element method; residual stresses; cartesian meshing; layered tetrahedral meshing; 23 European Conference on Fracture - ECF23 Assessment of the cartesian and layered tetrahedral mesh strategies in the thermomechanical simulation of the selective laser melting process Harry O. Psihoyos a,* , George N. Lampeas a a Laboratory of Technology and Strength of Materials, Department of Mechanical Engineering & Aeronautics, University of Patras , Rion 26504, Greece Psihoy a,* a

* Corresponding author. Tel.: +30-2610-996364 ; fax: +30-2610-991626. E-mail address: psychogyios_charalampos@upnet.gr

2452-3216 © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of 23 European Conference on Fracture - ECF23

2452-3216 © 2022 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the 23 European Conference on Fracture – ECF23 10.1016/j.prostr.2022.12.037