Part-scale build orientation optimization for minimizing residual stress and support volume for metal additive manufacturing: Theory and experimental validation

• Published in: Computer aided design Vol. 113; pp. 1 - 23
• Main Authors: Cheng, Lin, To, Albert
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier Ltd 01.08.2019; Elsevier BV
• Subjects: Additive manufacturing; Anchors; Asymptotic methods; Complexity; Cracks; Deformation; Design for manufacturability; Finite element method; Inherent strain method; Laser cooling; Lattice structure; Manufacturability; Mesh generation; Metal additive manufacturing; Modelling; Multiple objective analysis; Optimization; Orientation; Particle swarm optimization; Powder beds; Residual stress; Stress concentration; Stress distribution; Substrates; Voxel-based mesh generation; Warpage; Inherent strain method; Lattice structure; Particle swarm optimization; Metal additive manufacturing; Voxel-based mesh generation

Laser powder bed metal additive manufacturing (AM) has been widely accepted by the industry to manufacture end-use components with complex geometry to achieve desirable performance (i.e. conformal cooling). However, residual stress and large deformation introduced in the laser AM process lead to sev...