Modelling and simulation of electron beam melting |
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Authors: | M F Zäh S Lutzmann |
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Affiliation: | (1) Institute for Machine Tools and Industrial Management (iwb), Boltzmannstr. 15, 85747 Garching, Germany;(2) iwb Application Center Augsburg, Beim Glaspalast 5, 86153 Augsburg, Germany; |
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Abstract: | In recent years, the scientific and industrial relevance of additive layer manufacturing (ALM) has grown. In the metal area
of ALM, the capacity of laser technologies is noticeably limited. This is mainly due to an inertial beam deflection device,
which is also referred to as a mirror galvanometer. In contrast, the electron beam technology offers high power density as
well as considerable scanning rates. Therefore, electron beam melting (EBM) seems to be suitable for processing a broad variety
of alloys in an economic way. In particular, the enormous scanning rates which can be realized by use of an electron beam
enable an economic manufacture of high quality parts. However, profound expertise is required in order to establish EBM as
an industrial production technology. By means of mathematical–physical modelling, process stability of the melting step is
being increased. Moreover, by solving a detailed thermal model using the finite element method (FEM), substantial knowledge
of adequate parameter settings in dependence of the utilised material is developed. Finally, a process window as a function
of scan speed and beam power is developed based on experimental results. |
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