In this paper, a calibrated, fast, multiscale thermal model coupled with a 3D finite element mechanical model is used to simulate residual stress formation and deformations during selective laser melting. The resulting reduction in thermal model computation time allows evolutionary algorithm-based optimization of the process. A multilevel optimization strategy is adopted using a customized genetic algorithm developed for optimizing cellular scanning strategy for selective laser melting, with an objective of reducing residual stresses and deformations. The resulting thermo-mechanically optimized cellular scanning strategies are compared with standard scanning strategies and have been used to manufacture standard samples.
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Sankhya Mohanty, Jesper Henri Hattel, "Reducing residual stresses and deformations in selective laser melting through multi-level multi-scale optimization of cellular scanning strategy," Proc. SPIE 9738, Laser 3D Manufacturing III, 97380Z (6 April 2016);