Enhancement of the spreading process in additive manufacturing through the spreader optimisation

S. Haeri*

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract / Description of output

Powders used in Particle Bed Fusion (PBF) process are spread onto compact layers and then are sintered. This process is repeated layer by layer to form the final products. The author has recently characterised the process and it is found that spreading the particles with a counter-rotating roller produces a bed with higher qualities, i.e. lower void fractions and surface roughness [Powder Technology, 306 (2017) 45-54]. This is related to a particle dragging effect caused by the small contact area between powder grains and the blade. Therefore, here, it is postulated that changing the blade profile at the bladebed contact point can significantly influence the contact dynamics and hence increase the blade's effectiveness as a spreading device for PBF. A set of computer simulations using Discrete Element Method (DEM) are performed at device scales to optimise the geometry of blade spreaders to yield the lowest void fraction and surface roughness. The blade profile is parametrised using a super-ellipse with three geometrical parameters. It is firstly demonstrated that geometric optimisation of a blade profile is an effective alternative to using more complex spreading devices. Secondly, for the proposed parametrisation, the optimum values are found using computer simulations which can generate very high quality powder beds with volume fractions close to the critical value.

Original languageEnglish
Title of host publication5th International Conference on Particle-Based Methods - Fundamentals and Applications, PARTICLES 2017
EditorsE. Onate, P. Wriggers, T. Zohdi, M. Bischoff, D.R.J. Owen
PublisherInternational Center for Numerical Methods in Engineering
Pages409-419
Number of pages11
ISBN (Electronic)9788494690976
Publication statusPublished - Sept 2017
Event5th International Conference on Particle-Based Methods - Fundamentals and Applications, PARTICLES 2017 - Hannover, Germany
Duration: 26 Sept 201728 Sept 2017

Publication series

Name5th International Conference on Particle-Based Methods - Fundamentals and Applications, PARTICLES 2017

Conference

Conference5th International Conference on Particle-Based Methods - Fundamentals and Applications, PARTICLES 2017
Country/TerritoryGermany
CityHannover
Period26/09/1728/09/17

Keywords / Materials (for Non-textual outputs)

  • Additive Manufacturing
  • DEM
  • Optimisation
  • Particle Bed Fusion
  • Powder Spreading

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