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<p>The selective laser melting (SLM) process involves complex thermophysical interactions, which almost inevitably generate stress and deformation. It is difficult to make efficient and accurate analysis of stress and deformation, and it is time-consuming for calculating residual stress and deformation by existing thermomechanical coupling models. The inherent strain method can efficiently simulate the overall residual stress and deformation of parts, but the existing inherent strain method is limited to calculating simple trajectories in thermoplastic models. Furthermore, the method of extracting inherent strain has a significant impact on the accuracy of the overall results. This paper proposes a further optimization method for correcting inherent strain (ISM) and establishes a thermomechanical coupling optimization model through a multiphysics simulation platform. It proposes a mid-level partitioning method to avoid the influence of differences in inherent strain coefficients between the border and the middle region and achieve effective extraction of inherent strain values for any complex trajectory. By using a line heat source for reciprocating scanning trajectories, the single-layer simulation time is reduced from 2.5&#xa0;hours to an average of 15&#xa0;minutes. Combined with the border filling scanning method, the inherent strain value extraction of the variable parameter scanning mode is achieved, which improves simulation efficiency while ensuring simulation accuracy. The simulation time of the part-scale model is within 25&#xa0;minutes by using the inherent strain method. The material used in this study was Inconel 718. The deformation distribution obtained from simulation is basically consistent with experimental measurements, with an overall maximum size error of only 4.03%, a maximum deformation difference of 0.21&#xa0;mm, and a maximum relative error of 25.4%. Combined with experimental data, it is shown that the optimized inherent strain method can efficiently and accurately predict the deformation generated by SLM machining parts, providing reference for subsequent SLM research.</p>

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Optimization of Modified Inherent Strain Method Based on Thermomechanical Coupling and Validation of Selective Laser Melting Process

  • 期刊论文

  • 发表日期：

    2025年10月29日

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  • Peng Dai,
  • Bo Qian,
  • Man Zhao,
  • Hao Zhou,
  • Qingsong Wei,
  • Zhongliang Lu

摘要

The selective laser melting (SLM) process involves complex thermophysical interactions, which almost inevitably generate stress and deformation. It is difficult to make efficient and accurate analysis of stress and deformation, and it is time-consuming for calculating residual stress and deformation by existing thermomechanical coupling models. The inherent strain method can efficiently simulate the overall residual stress and deformation of parts, but the existing inherent strain method is limited to calculating simple trajectories in thermoplastic models. Furthermore, the method of extracting inherent strain has a significant impact on the accuracy of the overall results. This paper proposes a further optimization method for correcting inherent strain (ISM) and establishes a thermomechanical coupling optimization model through a multiphysics simulation platform. It proposes a mid-level partitioning method to avoid the influence of differences in inherent strain coefficients between the border and the middle region and achieve effective extraction of inherent strain values for any complex trajectory. By using a line heat source for reciprocating scanning trajectories, the single-layer simulation time is reduced from 2.5 hours to an average of 15 minutes. Combined with the border filling scanning method, the inherent strain value extraction of the variable parameter scanning mode is achieved, which improves simulation efficiency while ensuring simulation accuracy. The simulation time of the part-scale model is within 25 minutes by using the inherent strain method. The material used in this study was Inconel 718. The deformation distribution obtained from simulation is basically consistent with experimental measurements, with an overall maximum size error of only 4.03%, a maximum deformation difference of 0.21 mm, and a maximum relative error of 25.4%. Combined with experimental data, it is shown that the optimized inherent strain method can efficiently and accurately predict the deformation generated by SLM machining parts, providing reference for subsequent SLM research.