Support design of overhanging structure for laser powder bed fusion

Gaolin Yang; Hejie Li; Zishan Li; Zhaoheng Zhu; Rong Liu; Qunli Zhang; Yunfeng Liu; Jianhua Yao

Journal of Materials Research and Technology (May 2023)

Support design of overhanging structure for laser powder bed fusion

Gaolin Yang,
Hejie Li,
Zishan Li,
Zhaoheng Zhu,
Rong Liu,
Qunli Zhang,
Yunfeng Liu,
Jianhua Yao

Affiliations

Gaolin Yang: College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China; Institute of Laser Advanced Manufacturing, Zhejiang University of Technology, Hangzhou, 310023, China; Collaborative Innovation Center of High-end Laser Manufacturing Equipment (National “2011 Plan”), Zhejiang University of Technology, Hangzhou, 310023, China
Hejie Li: College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China; Institute of Laser Advanced Manufacturing, Zhejiang University of Technology, Hangzhou, 310023, China; Collaborative Innovation Center of High-end Laser Manufacturing Equipment (National “2011 Plan”), Zhejiang University of Technology, Hangzhou, 310023, China
Zishan Li: College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China; Institute of Laser Advanced Manufacturing, Zhejiang University of Technology, Hangzhou, 310023, China; Collaborative Innovation Center of High-end Laser Manufacturing Equipment (National “2011 Plan”), Zhejiang University of Technology, Hangzhou, 310023, China
Zhaoheng Zhu: College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China; Institute of Laser Advanced Manufacturing, Zhejiang University of Technology, Hangzhou, 310023, China; Collaborative Innovation Center of High-end Laser Manufacturing Equipment (National “2011 Plan”), Zhejiang University of Technology, Hangzhou, 310023, China
Rong Liu: Department of Mechanical and Aerospace Engineering, Carleton University, 1125 Colonel By Drive, Ottawa, Ontario, K1S 5B6, Canada
Qunli Zhang: College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China; Institute of Laser Advanced Manufacturing, Zhejiang University of Technology, Hangzhou, 310023, China; Collaborative Innovation Center of High-end Laser Manufacturing Equipment (National “2011 Plan”), Zhejiang University of Technology, Hangzhou, 310023, China
Yunfeng Liu: College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China
Jianhua Yao: College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China; Institute of Laser Advanced Manufacturing, Zhejiang University of Technology, Hangzhou, 310023, China; Collaborative Innovation Center of High-end Laser Manufacturing Equipment (National “2011 Plan”), Zhejiang University of Technology, Hangzhou, 310023, China; Corresponding author.

Journal volume & issue: Vol. 24
pp. 8693 – 8702

Abstract

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Warpage deformation inevitably occurs when laser powder bed fusion (LPBF) is applied on an overhanging structure. An effective support added to the system can mitigate warpage and improve the accuracy of formed parts. Four types of support structures are designed, and sheet tensile specimens and overhanging structures with different support structures are fabricated in this study. The tensile failure behavior and warpage suppression ability of different support structures are investigated, with the relation of the support influence to the design of support structure analyzed. The results show that the support with reinforcement can effectively restrain warpage deformation of the overhanging structure. During the process of tension, the main failure area of the support structure is located on the top of the support structure, close to the overhanging solid body. Increasing the change ratio of the support cross-sectional area is helpful to improve the constraint ability of the support. This design provides a new method for accurate forming of overhanging structures via LPBF and evaluating the restrain ability of support structures.

Published in Journal of Materials Research and Technology

ISSN: 2238-7854 (Print); 2214-0697 (Online)
Publisher: Elsevier
Country of publisher: Netherlands
LCC subjects: Technology: Mining engineering. Metallurgy
Website: https://www.journals.elsevier.com/journal-of-materials-research-and-technology/

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