Pitt to Develop Modeling and Simulation Methods

Manufacturers can use additive manufacturing to create complex metal components, but these applications can be plagued by defects and distortions caused by the properties of the material, and quality standards for component testing are still developing. More advanced modeling and simulation technology would help, and that’s precisely what researcher at the University of Pittsburgh’s Swanson School of Engineering plan to develop thanks to a grant from the National Science Foundation (NSF).

“Multiscale Structure-Mechanical Property Investigation of Additive Manufactured Components for Development of a Reliable Qualification Method” is a three-year, $300,000 grant funded by the NSF’s Division of Civil, Mechanical and Manufacturing Innovation (CMM) for developing standard qualification methods for AM.

On the modeling and simulation front, the University has received a $150,000 Research for Additive Manufacturing in Pennsylvania (RAMP) grant for its “Automation Tools for Modeling AM Process of Complex Geometries in ABAQUS” project. RTI International Metals of Pittsburgh will partner with Pitt on this project.

Principal investigator for both grants is Albert To, PhD, associate professor of mechanical engineering and materials science. The co-investigators are Minking K. Chyu, PhD, the Leighton and Mary Orr Chair professor of materials science and mechanical engineering, associate dean for international initiatives and dean of the Sichuan University–Pittsburgh Institute; and Markus Chmielus, PhD, assistant professor of mechanical engineering and materials science. According to Dr. To:

Additive manufacturing continues to demonstrate its ability to manufacture very complex lattice structures and geometries, enabling us to build complex structures that would be difficult to replicate using traditional or ‘subtractive’ manufacturing. However, these increasingly complex parts are very time-consuming to model and therefore more prone to errors. The RAMP grant will enable us to develop computer codes that first will automate the finite element simulation of certain AM process and material. By improving the modeling of these complex, sometimes microscopic structures, we can design the process path and/or part geometry to reduce residual stress that causes failure to the part during manufacturing.

Better modeling and simulation processes will be a key part of developing new qualification methods, in conjunction with the use of CT scan equipment. The researchers will be able to investigate the mechanical effects of flaws and residual stress at the microscopic level, and develop a computer-based, non-destructive method for rapidly testing AM party quality.

Source: University of Pittsburgh