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  Virtual Additive Manufacturing - full-scale computer simulation tool for powder bed fusion


   Department of Mathematics

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  Dr A Cangiani, Prof J Pan  No more applications being accepted  Competition Funded PhD Project (Students Worldwide)

About the Project

Numerical simulation of additive manufacturing (AM) processes based on electron or laser beam melting of metals. Outcome: full-scale computer simulation tool for powder bed fusion.
1 Convergence analysis of Material Point Method (MPM)
2 Linear FE-MPM parallel implementation.
3 Interfacing with real 3D-printing geometries (CAD/STL) and scans (G-code).
4 Implementation of VEM for transient elastic problem.
5 Combine MPM with VEM on given locally refined mesh, including local time-stepping.
6 A posteriori error analysis and adaptivity for efficient resolution of practical test cases.

A major challenge with AM is poor repeatability of mechanical properties. Computer simulations offer a framework for investigating such problem, as opposed to an expensive trial and error experimentation. However, classical FE analysis is ill-suited as parts may experience sophisticated topology and due to multi-scale nature of the problem.
The development of a realistic and efficient AM direct is thus crucial in view of making 3D printing based on AM a viable industrial paradigm.
MPM and VEM, have never been applied to this problem. Moreover, the idea of combining them is entirely new.

Funding Notes

IMPaCT students are fully funded studentships which include:
• A full UK/EU fee waiver for 4 years
• An annual tax free stipend of £14,777 (2018/19)
• Possibility of additional top up for industry sponsored projects.
• Generous Research Training Support Grant.
Studentships are open to UK Home / EU applicants who meet the residency criteria which is set out by the Research Council EPSRC.
A limited amount of partial funding is available for exceptional international applicants who are highly qualified and motivated. Due to the nature of this funding, the CDT would only be able to cover the cost of the Home/EU fees and therefore the applicant would need to either find alternative funding or self-fund the fee difference

References

L. Beirao da Veiga, F. Brezzi, A. Cangiani, G. Manzini, D.L. Marini and A. Russo. Basic principles of Virtual Element Methods. Mathematical Models and Methods in Applied Sciences, Vol. 23(1), 199–214, 2013.

Z. Wieckowski. The material point method in large strain engineering problems. CMAME, Vol. 193(39-41), 4417–4438, 2004.

A.V. Gusarov and I. Smurov. Modeling the interaction of laser radiation with powder bed at selective laser melting. Physics Procedia, Vol. 5, 381–394, 2010.