Mesoscale modeling of stress and strain evolution in electron beam powder bed fusion additive manufacturing (EB-PBF)
department or school: Applied Science, Faculty of
department or school: Materials Engineering, Department of
data provider: DSpace
degree campus: UBCV
creator: Chakraborty, Asmita
issued: 2022-05-20T17:55:33Z
issued: 2022
related degree: Master of Applied Science - MASc
degree grantor: University of British Columbia
description: Components manufactured using the Electron Beam Powder Bed Fusion (EB-PBF) Additive Manufacturing method are often prone to deformation and residual stress caused by the repeated heating, melting, solidification, and cooling that occurs during the process. The presence of residual stress can reduce the service life of the parts. An estimation of the magnitude, state, and distribution of residual stress can aid in maintaining the dimensional accuracy of the component. Although effort has been made to understand the residual stress development in EB-PBF, understanding the complicated interaction between a newly deposited powder layer and the consolidated layer is still in its infancy. In this study, a coupled thermomechanical model was built to examine the buildup of stress and inelastic strain during the layer-by-layer processing of a part at the mesoscale level. A small mesoscale domain was developed to represent a volume extracted from within a much larger component. The sub-domain dimensions were chosen to include the total thickness of four powder layers and a section of previously deposited material equivalent to approximately eight consolidated layers. The model uses a novel approach to capture the transition in material response when the material changes from powder to liquid to solid. A user-defined subroutine was developed to correctly describe the evolution of thermal strain as the material solidifies and contracts. The mesoscale model developed in this work has been used to examine different scenarios. The effect of substrate temperature, electron beam power, and scan speed on the residual stress and deformation were examined. The numerical results show that a compressive plastic strain field forms in proximity to the melt pool. The model also indicates that within the temperature range of 630 ℃ to 730 ℃, a 50 ℃ increase in substrate temperature leads to a ~21% decrease in the in-elastic strain magnitude. Within the beam power range of 740 W to 940 W, the …
aggregated CHO: https://circle.library.ubc.ca/rest/handle/2429/81618
note: Mesoscale Modeling of Stress and Strain Evolution in Electron Beam Powder Bed Fusion Additive Manufacturing (EB-PBF) by Asmita Chakraborty B.E., Indian Institute of Engineering, Science & Technology, Shibpur, 2017 A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF APPLIED SCIENCE in The Faculty of Graduate and Postdoctoral Studies (Materials Engineering) THE UNIVERSITY OF BRITISH COLUMBIA (Vancouver) May 2022 © Asmita Chakraborty, 2022 ii The following individuals certify that they have read, and recommend to the Faculty of Graduate and Postdoctoral Studies for acceptance, the thesis entitled: Mesoscale Modeling of Stress and Strain Evolution in Electron Beam Powder Bed Fusion Additive Manufacturing (EB-PBF) submitted by Asmita Chakraborty in partial fulfillment of the requirements for the degree of Master of Applied Science in Materials Engineering Examining Committee: Dr. Steve Cockcroft, Professor, Materials Engineering, UBC Co-Supervisor Dr. Daan Maijer, Professor, Materials Engineering, UBC Co-Supervisor Dr. Farzaneh Farhang Mehr, Director of Additive Manufacturing, Materials Engineering, UBC Supervisory Committee Member Dr. Tom Troczynski, Professor, Materials Engineering, UBC Supervisory Committee Member Dr. Chad Sinclair, Professor, Materials Engineering, UBC Supervisory Committee Member Dr. Yasmin Abedin, Assistant Professor, Materials Engineering, UBC Supervisory Committee Member iii Abstract Components manufactured using the Electron Beam Powder Bed Fusion (EB-PBF) Additive Manufacturing method are often prone to deformation and residual stress caused by the repeated heating, melting, solidification, and cooling that occurs during the process. The presence of residual stress can reduce the service life of the parts. An estimation of the magnitude, state, and distribution of residual stress can aid in maintaining the dimensional accuracy of the component. Although effort has been made to understand the residual stress…
has type: Thesis/Dissertation
date issued: 2022-11
is shown at: 10.14288/1.0413677
language: eng
degree discipline: Materials Engineering
provider: Vancouver : University of British Columbia Library
publisher: University of British Columbia
rights: Attribution-NonCommercial-NoDerivatives 4.0 International
rights URI: http://creativecommons.org/licenses/by-nc-nd/4.0/
scholar level: Graduate
contributor: Cockcroft, Steve L.
contributor: Maijer, Daan M.
type: Text
identifier URI: http://hdl.handle.net/2429/81618