TY - JOUR
T1 - AM-FEMU
T2 - An optimization method for additive manufacturing simulation parameters based on finite element model updating, utilizing three-dimensional deformation and melt pool temperature fields
AU - Chen, Ru
AU - Xue, Hanwen
AU - Zhong, Qixian
AU - Zhang, Chenghao
AU - Li, Shiqing
AU - Geng, Chuanqing
AU - Zhao, Jiaye
AU - Liu, Zhanwei
AU - Xie, Huimin
AU - Zhang, Zhanfei
N1 - Publisher Copyright:
© 2025 Elsevier Ltd
PY - 2025/4
Y1 - 2025/4
N2 - Accurate model parameters are crucial for reliable metal additive manufacturing (AM) simulations, which are essential for understanding AM material formation mechanisms, designing AM components, and controlling manufacturing processes. This study addresses the discrepancy between AM simulations and experimental results by developing an Additive Manufacturing Finite Element Model Updating (AM-FEMU) method. The AM-FEMU method updates and optimizes the simulation parameters based on the temperature field of the melt pool and the deformation field of the substrate during the AM process. Online measurements of three-dimensional displacement and melt pool temperature were conducted using three-dimensional sampling moiré and multi-spectral colorimetric temperature measurement technologies. By comparing these measurements with finite element (FE) simulation, the heat source parameters and thermal expansion coefficient were updated successfully. Verification tests confirmed that the updated parameters significantly improved the accuracy of residual stress in AM simulations compared to the original parameters. This method promotes the application of FEMU in metal AM simulations, further providing a deeper understanding of the physical mechanism in metal AM process.
AB - Accurate model parameters are crucial for reliable metal additive manufacturing (AM) simulations, which are essential for understanding AM material formation mechanisms, designing AM components, and controlling manufacturing processes. This study addresses the discrepancy between AM simulations and experimental results by developing an Additive Manufacturing Finite Element Model Updating (AM-FEMU) method. The AM-FEMU method updates and optimizes the simulation parameters based on the temperature field of the melt pool and the deformation field of the substrate during the AM process. Online measurements of three-dimensional displacement and melt pool temperature were conducted using three-dimensional sampling moiré and multi-spectral colorimetric temperature measurement technologies. By comparing these measurements with finite element (FE) simulation, the heat source parameters and thermal expansion coefficient were updated successfully. Verification tests confirmed that the updated parameters significantly improved the accuracy of residual stress in AM simulations compared to the original parameters. This method promotes the application of FEMU in metal AM simulations, further providing a deeper understanding of the physical mechanism in metal AM process.
KW - Additive manufacturing
KW - Finite element model updating
KW - Melt pool temperature field
KW - Online monitoring
KW - Three-dimensional deformation field
UR - http://www.scopus.com/inward/record.url?scp=85215420511&partnerID=8YFLogxK
U2 - 10.1016/j.tws.2025.112962
DO - 10.1016/j.tws.2025.112962
M3 - Article
AN - SCOPUS:85215420511
SN - 0263-8231
VL - 209
JO - Thin-Walled Structures
JF - Thin-Walled Structures
M1 - 112962
ER -