Session: 03-08-01: Computational Modeling and Simulation for Advanced Manufacturing

Paper Number: 144314

144314 - Using the Gurson-Tvergaard-Needleman Model for Ductile Fracture Prediction in Metal Additive Manufacturing of 17-4ph 

This document delves deeper into the forefront of Metal Additive Manufacturing (Metal AM), a standout sector known as 3D printing. This field is celebrated for its remarkable potential in enabling high levels of customization, ensuring cost-efficiency, and promoting environmentally sustainable manufacturing practices. Metal AM is redefining the approach to creating metallic components, offering innovative methodologies that are shaping the future of manufacturing. Despite its numerous advantages, Metal AM faces significant challenges that need to be addressed to fully realize its potential. One of the primary concerns is the issue of part durability and strength, which can sometimes fall short when compared to parts produced through traditional manufacturing methods. These challenges are predominantly due to various defects inherent to the additive manufacturing process, such as porosity, inclusions, and residual stress. Porosity, for example, refers to the presence of tiny holes or voids within the printed material, which can significantly undermine the mechanical strength and fatigue resistance of the parts. Inclusions, on the other hand, are foreign particles or materials that become embedded within the metal during the printing process, potentially leading to weak points within the material. Residual stress is another critical concern, arising from the rapid cooling and solidification processes inherent in Metal AM, which can lead to warping, distortion, or even cracking of the component. The focus of this research is an in-depth analysis of ductile fracture in Metal AM components, utilizing the esteemed Gurson-Tvergaard-Needleman (GTN) model. This model is a well-recognized numerical tool in the study of ductile fracture, adept at simulating the initiation, growth, and coalescence of microvoids and cavities within metallic materials, culminating in fracture. Our study adapts the GTN model to the specific nuances of Metal AM, aiming to provide a comprehensive strategy to analyze and predict the behavior of Metal AM materials in the face of these ductile fractures. This involves detailed computational simulations complemented by empirical validation, focusing on understanding the unique microstructural features brought about by Metal AM and how they interact with the aforementioned defects. The findings from our research offer new insights into the mechanisms of fracture in Metal AM components, enhancing our understanding of their behavior and providing a robust framework for assessing their structural integrity in the face of various manufacturing defects. By advancing our knowledge of the mechanical properties of Metal AM materials, particularly in relation to their defect-related vulnerabilities, this study not only contributes to the field of material science but also aids in refining the Metal AM process itself. This is crucial for the ongoing development and innovation within the Metal Additive Manufacturing industry, ensuring its sustainable growth and successful integration into the broader manufacturing system.

Presenting Author: Moon Ki Kim Sungkyunkwan University

Presenting Author Biography: Moon Ki Kim received B.S. and M.S. degrees in Mechanical Engineering from Seoul National University in 1997 and 1999, respectively, and Ph.D. degree from Johns Hopkins University in 2004. He had been an Assistant Professor in the Department of Mechanical and Industrial Engineering at University of Massachusetts, Amherst from 2004 to 2008. In 2008, he joined Sungkyunkwan University, where he is currently a Professor in School of Mechanical Engineering. His research interests are focused on computational structural biology based on robot kinematics, bioinstrumentations, and multiscale modeling and simulation.

Authors:

Yonghwi KIM Sungkyunkwan University
Sangyeop Kim Sungkyunkwan University
Min-Kyeom Kim Sungkyunkwan University
Taeksang Lee Myongji University
Moon Ki Kim Sungkyunkwan University