Modeling and Simulation of Laser Processing of Particulate-Functionalized Materials

The objective of this paper is to focus on one of the “building blocks” of additive manufacturing technologies, namely selective laser-processing of particle-functionalized materials. Following a series of work in Zohdi (Int J Numer Methods Eng 53:1511–1532, 2002; Philos Trans R Soc Math Phys Eng Sci 361(1806):1021–1043, 2003; Comput Methods Appl Mech Eng 193(6–8):679–699, 2004; Comput Methods Appl Mech Eng 196:3927–3950, 2007; Int J Numer Methods Eng 76:1250–1279, 2008; Comput Methods Appl Mech Eng 199:79–101, 2010; Arch Comput Methods Eng 1–17. doi: 10.1007/s11831-013-9092-6, 2013; Comput Mech Eng Sci 98(3):261–277, 2014; Comput Mech 54:171–191, 2014; J Manuf Sci Eng ASME doi: 10.1115/1.4029327, 2015; CIRP J Manuf Sci Technol 10:77–83, 2015; Comput Mech 56:613–630, 2015; Introduction to computational micromechanics. Springer, Berlin, 2008; Introduction to the modeling and simulation of particulate flows. SIAM (Society for Industrial and Applied Mathematics), Philadelphia, 2007; Electromagnetic properties of multiphase dielectrics: a primer on modeling, theory and computation. Springer, Berlin, 2012), a laser-penetration model, in conjunction with a Finite Difference Time Domain Method using an immersed microstructure method, is developed. Because optical, thermal and mechanical multifield coupling is present, a recursive, staggered, temporally-adaptive scheme is developed to resolve the internal microstructural fields. The time step adaptation allows the numerical scheme to iteratively resolve the changing physical fields by refining the time-steps during phases of the process when the system is undergoing large changes on a relatively small time-scale and can also enlarge the time-steps when the processes are relatively slow. The spatial discretization grids are uniform and dense enough to capture fine-scale changes in the fields. The microstructure is embedded into the spatial discretization and the regular grid allows one to generate a matrix-free iterative formulation which is amenable to rapid computation, with minimal memory requirements, making it ideal for laptop computation. Numerical examples are provided to illustrate the modeling and simulation approach, which by design, is straightforward to computationally implement, in order to be easily utilized by researchers in the field. More advanced conduction models, based on thermal-relaxation, which are a key feature of fast-pulsing laser technologies, are also discussed.