
Particle Finite Element Method based modelling of Additive Manufacturing
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Directed Energy Deposition with a Laser Beam (DED-LB) is an Additive Manufacturing technique for the production of high-strength steel components for various engineering applications. Modelling of DED-LB using a finite element approach represents a compromise between accuracy and computational efficiency. Conventional models require a predefined geometry of the deposited material, which is then activated sequentially during the simulation. However, this approach does not resolve the real material interactions during deposition and cannot model unpredictable melt flow in limit cases. The Particle Finite Element Method (PFEM) allows the simulation of very large material flows due to the frequent remeshing of the mostly unchanged set of nodes, and it still retains the strength of Lagrangian Finite Element Methods in accurately modelling history dependent material behaviour. This contribution presents a thermomechanical framework that adapts PFEM to the deposition process to model melt flow, bonding to the substrate, solidification and cooling. The constitutive behaviour is governed by a large-strain material model for the transition from a Maxwell-type viscous fluid to elastic or elastoplastic behaviour in the solid. The inclusion of latent heat and transformation strains is important to accurately predict residual stresses. The present contribution discusses the required developments of remeshing methods to account for the connection with the substrate as well as methods for improving the quality of the point distribution. Thereby, the model from [1] is extended to 3d space which increases the mesh complexity and requires more refined techniques to guarantee a well-shaped and filled connection layer as well as quality tetrahedral meshes. The examples are referred to experimental investigations of a single weld bead which is produced by our project partner at the Institute of Forming Technology and Lightweight Components, TU Dortmund University, as part of DFG grant 504955789. [1] Schewe, M., Noll, I., Bartel, T., and Menzel, A. Towards the simulation of metal deposition with the Particle Finite Element Method and a phase transformation model. Computer Methods in Applied Mechanics and Engineering. 437, 117730 (2025). https://doi.org/10.1016 j.cma.2025.117730.