A Numerical Model for Simulating the Selective Laser Melting of Closed Impellers

The Selective Laser Melting (SLM) is accelerating the adoption of Additive Manufacturing (AM) technologies in the industry. One of the most critical benefits concerns the possibility of manufacturing complex-shaped components, which are not feasible or too expensive using traditional processes. Recent studies are evaluating the SLM manufacturability of closed impellers through laboratory tests. The adoption of numerical simulation models for achieving this goal is still limited due to the complexity of the additive process and the number of phases to be considered. The paper presents a numerical model developed in the ANSYS workbench platform for simulating the SLM process of closed impellers. This work is one of the first studies available in the literature for such a particular kind of components. The paper describes the overall simulation model and the steps required for its definition. Furthermore, boundary conditions and process parameters are provided for a better understanding of the model. A case study illustrates its application to a specific part, intending to evaluate (i) impact between the recoater and the component, (ii) maximum von Mises stress and (iii) maximum displacement during the printing phase and following post-processing. These evaluations will support design and manufacturing engineers during product and process engineering. The promising results of this study are encouraging further research about the application of SLM for closed impellers.