FEM-Based Simulative Study for Multi-Response Optimization of Powder Bed Fusion Process

Laser powder bed fusion (LPBF) is an additive manufacturing technology which uses a heat source (laser) to sinter or fuse atomized particles together. A new layer of spread over the previous using roller, and then laser power fuses them. This mechanism repeated until part model completed. To reduce time, effort, cost, present study incorporated design experimental approach conjoined with finite element analysis (FEA) simulate LPBF process. three-dimensional (3D) bi-material was subjected FEA variations in temporal spatial material characteristics. Gaussian moving for multi-scanning single developed understand effect process parameters, namely power, scan speed, pattern on melt pool dimensions. Although, similar simulation models have been reported literature, majority these did not consider parametric variations. few studies adopted multiple parameters varied simultaneously, but major limitation that most them characteristics under constrained environment. In research, multi-parameter multi-level performed fewer simulations. Results showed studied dimensions were sensitive parameter setting, temperature variation within dependant phase vicinity pool. research proposed must be accurately controlled optimum performance achieve proper overlap between adjacent lines sufficient depth complete bonding bottom layer. Since involved criteria conflicting nature, problem determining factor setting obtain desired results solved grey relational (GRA). It found that, among all considered velocity significant one. recommended maximum i.e., v = 1.5 m/s, minimum P 80 W. addition, it also suggested low energy density used properly.