Multi-Resolution SPH Simulation of a Laser Powder Bed Fusion Additive Manufacturing Process

This paper presents an efficient mesoscale simulation of a Laser Powder Bed Fusion (LPBF) process using the Smoothed Particle Hydrodynamics (SPH) method. The efficiency lies in reducing the computational effort via spatial adaptivity, for which a dynamic particle refinement pattern with an optimized neighbor-search algorithm is used. The melt pool dynamics is modeled by resolving the thermal, mechanical, and material fields in a single laser track application. After validating the solver by two benchmark tests where analytical and experimental data are available, we simulate a single-track LPBF process by adopting SPH in multi resolutions. The LPBF simulation results show that the proposed adaptive refinement with and without an optimized neighbor-search approach saves almost 50% and 35% of the SPH calculation time, respectively. This achievement enables several opportunities for parametric studies and running high-resolution models with less computational effort.