Deformation prediction and shape compensation model of circular channels using laser powder bed fusion

Abstract

Laser powder bed fusion (L-PBF) technology offers significant advantages, such as lightweight and miniaturized product fabrication and short manufacturing cycles. Circular channels are widely utilized in hydraulic manifold blocks due to their favorable hydrodynamic properties. However, when manufactured using L-PBF, circular channels often exhibit shape deviations caused by residual stresses. In this study, Ti6Al4V (TC4) circular channels with various processing parameters were produced through L-PBF. The influence of scanning speed and laser power on the actual channel profile was investigated. A novel deformation prediction model for circular channels was established based on the Euler–Bernoulli theory. This model accurately predicts deformations resulting from residual stresses during horizontal manufacturing of circular channels using L-PBF, considering the interaction between forces and deformations across different manufactured layers. Furthermore, the model can be employed for channel shape compensation design. The results indicated excellent agreement between the proposed deformation prediction model and the profile of the experimentally manufactured samples. Using the channel shape compensation model for circular channels substantially can reduce the root mean square (RMS) deviation, thereby improving dimensional accuracy.

Keywords

• Laser powder bed fusion
• Circular channel
• Residual stress
• Deformation prediction
• Shape compensation