Additive manufacturing: direct-energy-deposition process parameters optimisation via simulation (B)

• Main Author: Chua, Wei Bin
• Other Authors: Li Hua
• Format: Final Year Project
• Language: English
• Published: Nanyang Technological University 2024
• Subjects: Engineering; Additive manufacturing; Direct energy deposition; Nozzle; Computational fluid dynamics; Simulation; Coefficient of restitution; Wall roughness
• Online Access: https://hdl.handle.net/10356/177342
• Institution: Nanyang Technological University

This Final Year Project (FYP) systematically investigates the optimization of process parameters within the Directed Energy Deposition (DED) technique of Additive Manufacturing (AM), focusing on the impacts of wall boundary conditions such as the Coefficient of Restitution (COR) and wall roughness. Utilizing advanced Computational Fluid Dynamics (CFD) simulations, this study aims to enhance the accuracy and reliability of modeling DED processes, which are critical for high-quality manufacturing. Extensive simulations were conducted using various meshing strategies to ascertain their influence on simulation fidelity. The findings indicate that polyhedral meshing significantly improves simulation accuracy due to its superior handling of complex geometries and computational efficiency. Additionally, the research established that while the COR significantly affects particle behaviour within the nozzle, influencing energy dissipation and particle dispersion, wall roughness does not exhibit a notable impact on the DED outcomes.