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US 12,608,514 B1Granted
Determination of heat source absorptivity and penetration depth in additive manufacturing melt pools
AssigneeAnsys, Inc.
InventorsZack Francis, Chong Teng, Hai Dong
Life of this patent
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Abstract
Computer-implemented systems and methods are described herein for determining additive manufacturing parameters in a simulation. Input data regarding a product to be generated via additive manufacturing and a beam diameter are received. Based on the input data, a characteristic dimension is determined. The beam diameter is normalized based on the characteristic dimension. Additive manufacturing parameters, such as penetration depth and absorptivity, are determined based on the normalized beam diameter and experimentally-determined trends. The manufacturing of the product is then simulated according to the additive manufacturing parameters.
Claims20
A computer-implemented method for providing a digital computer simulation for calculating additive manufacturing parameters comprising:
- accessing experimental data characterizing general melt pool dimensions for a given material, the experimental data being based on a plurality of manufacturing experiments performed using an additive manufacturing system, the experiments being for a given substrate using varying speed and input parameters of the additive manufacturing system;
- generating, by at least one data processor, a look-up table based on the experiments, the look-up table correlates parameters used for the experiments to a characteristic dimension;
- receiving, by at least one data processor, input data regarding a product to be generated via additive manufacturing and a beam diameter;
- determining, by at least one data processor, that an entry corresponding to the received input data is not in the look-up table;
- initializing, by at least one data processor and in response to the determination that an entry corresponding to the received input data is not in the look-up table, an interpolation model to determine a characteristic dimension based on the input data and the look-up table;
- normalizing, by at least one data processor, the beam diameter based on the beam diameter divided by the characteristic dimension;
- and
- simulating, by at least one data processor and using the initialized interpolation model, manufacturing of the product based on the input data and the normalized beam diameter to determine additive manufacturing parameters, the simulating comprising iterative simulations to generate additive manufacturing parameters until such time that values of the generated additive manufacturer parameters match the experimental data, the simulations being configured to eliminate effects of heat source parameters.
5 more elements
A computer-implemented system comprising:
- one or more data processors;
- one or more computer-readable storage mediums encoded with instructions for commanding the one or more data processors to execute operations comprising:
- receiving input data regarding a product to be generated via additive manufacturing and a beam diameter;
- determining that an entry corresponding to the received input data is not in a look-up table, the look-up table being generated by conducting experiments to obtain experimental data characterizing general melt pool dimensions for a given material based on a plurality of manufacturing experiments for a given substrate using varying speed and input parameters;
- initializing, in response to the determination that an entry corresponding to the received input data is not in the look-up table, an interpolation model to determine a characteristic dimension based on the input data and the look-up table;
- normalizing the beam diameter based on the characteristic dimension;
- and
- simulating, based on the initialized interpolation model, manufacturing of the product based on the input data and the normalized characteristic dimension to determine additive manufacturing parameters, the simulating comprising iterative simulations to generate additive manufacturing parameters until such time that values of the generated additive manufacturer parameters match experimental data generated from a plurality of manufacturing experiments for a given substrate using varying power and speed input parameters, the simulations being configured to eliminate effects of heat source parameters;
- wherein the product is built on the substrate by way of an additive manufacturing process using the generated additive manufacturing parameters having values that match the experimental data.
6 more elements
A non-transitory computer-readable storage medium comprising instructions for which when executed cause a processing system to execute operations comprising:
- receiving input data regarding a product to be generated via additive manufacturing and a beam diameter;
- determining that an entry corresponding to the received input data is not in a look-up table, the look-up table being generated by conducting experiments to obtain experimental data characterizing general melt pool dimensions for a given material based on a plurality of manufacturing experiments for a given substrate using varying speed and input parameters;
- determining, using an interpolation model and in response to determining that the entry corresponding to the received input data is not in the look-up table, a characteristic dimension based on the input data and the look-up table;
- normalizing the beam diameter based on the characteristic dimension;
- and
- simulating, based on the initialized interpolation model, manufacturing of the product based on the input data and the normalized characteristic dimension to determine additive manufacturing parameters, the simulating comprising iterative simulations to generate additive manufacturing parameters until such time that values of the generated additive manufacturer parameters match experimental data generated from a plurality of manufacturing experiments for a given substrate using varying power and speed input parameters, the simulations being configured to eliminate effects of heat source parameters;
- wherein the product is built on the substrate by way of an additive manufacturing process using the generated additive manufacturing parameters having values that match the experimental data.
4 more elements
Dependencies are inferred from the claim text.