Accuracy enhancement of additive manufacturing simulation for hot deformation reduction during AM

Abstract

In AM, hot deformation during manufacturing makes it difficult to receive the full benefit of the performance improvement by AM, because output shape deviates from the design shape. In order to cancel the deformation, the designed shape can be deformed beforehand in the opposite direction to the deformation, which is called the pre-deformation correction in this paper. The pre-deformation correction requires numerical calculation with both high-accuracy and low calculation cost to obtain the deformation on entire product surface beforehand by simulating the complicated process in which the material melts and solidifies ununiformly. In this paper, we propose a method to improve the AM simulation accuracy using inherent strain method, which has low calculation cost. The characteristic of this method is that the complex inherent strain distribution, which is simulation input, is estimated by Ridge regression from the trial manufacturing result. The effectiveness of the proposal method is shown using some specimens with different deformation modes.