Multiscale Simulation of DED Additive Manufacturing with an Arlequin-based Method
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Additive Manufacturing (AM), an advanced production technique that focuses on adding material, is transforming design capabilities and supporting sustainability by minimizing material and energy waste. A notable subset of AM methods is Direct Energy Deposition (DED), where material is continuously added as a heat source melts it, providing flexibility without constraints from enclosed environments. DED processes exhibit a dual nature in scales. On the micro scale, around the melt pool beneath the heat source, there are rapid melting and cooling effects. Conversely, on a larger scale, thermal changes lead to deformations, particularly noticeable in larger pieces. In response to the demand for numerical simulations in the AM industry, this study introduces an innovative Arlequin-based method \cite{arlequin}, contrasting with conventional activation methods \cite{quiet-inactive}. This approach employs two distinct meshes: a coarse mesh covering the entire domain and a fine mesh tracking the heat source to capture high thermal gradients. Operating in a reference frame transforms the moving fine mesh into a fixed one, simplifying calculations. Validation of the proposed method is done via a comprehensive set of analytical tests and experimental data.
