A finer modeling approach for numerically predicting single track geometry in two dimensions during Laser Rapid Manufacturing

We simulated the temperature distribution and single track geometry in Laser Rapid Manufacturing (LRM) of metal structures using two dimensional FEM with a finer modeling approach. This approach involved the calculation of excessive enthalpies above melting point for all nodal points in the process domain and using those for the computation of local track height at every node along the track width on the substrate. Laser power, laser beam size with its spatial profile, scan speed, powder feed rate and powder stream diameter with its flow distribution were taken as user-defined input parameters to simulate the single track geometry during LRM. The simulated results were experimentally verified. The percentage errors in simulated and corresponding experimental track heights along the normalized track width were calculated and compared with those of other existing models. With our modeling approach, the localized errors in predicting track geometries were found to be the least. This model is capable of dynamically predicting the temperatures and track geometry at various user-defined input parameters.

► The model simulates the temperature distribution and single track geometry. ► It calculates excessive enthalpies above melting point to estimate local track height. ► The model minimizes errors to average value of 2–5.6%. ► A comparison with other existing models is also presented.