Modelling and Numerical Simulation During Selective Laser Melting of Stainless Steel 316L Via Particle by Particle Approach

Additive manufacturing (AM) technology depends on the implemented selective laser melting (SLM) process. A good comprehension of its parameters is required to perform an efficient SLM process. Therefore, this study develops a computational fluid dynamic (CFD) model to simulate the SLM process based on a novel approach (particle by particle) and analyze its operating parameters. The model is based on the classical physics laws to formulate the governing equations and solve them in the ANSYS FLUENT software WORKBENCH R19.1. Melting of stainless steel 316L powder particles was considered a case study where laser power, scanning speed, and spot diameter were considered steady parameters. A User Define Function (UDF) is written in C -language to define the heat source and its parameters, and then it is run over the cell face center in every time step. A parametric study was conducted for three of the SLM main parameters; laser power, spot diameter, and scanning speed. The model was verified through the validation process, which confirmed the model's accuracy and reliability. The model outcomes revealed a proportional relationship between the laser power and each melting temperature and liquid mass fraction for a fixed spot diameter and scanning speed. Moreover, a higher energy density is achieved for a smaller laser spot diameter, which yields a higher liquid fraction and melt temperature.