Enhanced heat source modeling in particle-based laser manufacturing simulations with ray tracing

Particle-based spatial discretization methods such as smoothed particle hydrodynamics (SPH) possess suitability for the high-fidelity simulation of laser manufacturing processes due to their capability in treating complex free-surface and multiphase problems. In such simulations, laser heat source modeling remains a central concern as the mechanisms governing the material deformations and phase changes strongly depend on the input laser energy and its distribution details. Ray tracing (RT) is a realistic and accurate approach for high-fidelity heat source modeling that can capture surface heterogeneity and mul-tiple reflections. However, RT heat source modeling for particle-based numerical methods faces additional challenges rooted in the lack of explicit surface representation, intensive computational efforts, and im-plementation complexities. This work addresses these issues by proposing an enhanced and efficient RT heat source model for particle-based laser manufacturing simulations with negligible computational over-head and without requiring background nodes or surface mesh reconstruction. After validating the RT heat source model versus analytical and experimental results, we assess its computational performance through two test cases, showing that the computing workload imposed by our RT model is between 0.1% and 25% of the total runtime in different SPH-based laser manufacturing simulations. With the achieved efficiency and robustness, it becomes convenient yet advantageous to simulate processes like laser drilling and laser powder bed fusion with precision far beyond the conventional approaches using volumetric heat sources. & COPY; 2023 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license ( http://creativecommons.org/licenses/by-nc-nd/4.0/ )