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Simulation of 3D Volume Filling with Non-Spherical and Spherical Titanium Alloy Powder Particles for Additive Manufacturing

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Cybernetics and Systems Analysis Aims and scope

Abstract

The authors have developed an approach to modeling the layer-by-layer filling of the particular 3D volume with a combination of non-spherical and spherical powder particles of different fractional compositions. They have used the phi-function technique and constructed the mathematical model of the problem of packing regular and irregular freely moving objects. They also proposed the heuristic algorithm that uses nonlinear optimization for calculating packing density/porosity factor. The authors compared the results of numerical modeling with experimental data obtained for the mixture of spherical and polyhedral powders of titanium alloys. They have established that the percentage ratio of powder particles within the investigated fraction, obtained using the developed algorithm, corresponds with high accuracy to the experimental results. This finding indicates the possibility of using numerical modeling results instead of costly experimental studies. The use of mathematical modeling and optimization techniques in additive manufacturing makes it possible to improve the efficiency of each stage of the technological process, reduce the number of defective products, and rationally plan the consumption of energy and material resources.

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Authors and Affiliations

  1. A. Pidhornyi Institute of Mechanical Engineering Problems, National Academy of Sciences of Ukraine, Kharkiv, Ukraine

    Yu. Stoyan & O. Pankratov

  2. Lviv Polytechnic National University, Lviv, Ukraine

    I. Lemishka & Z. Duriagina

  3. University of Leeds, Leeds, England

    J. Bennell & T. Romanova

  4. A. Pidhornyi Institute of Mechanical Engineering Problems, National Academy of Sciences of Ukraine, Kharkiv National University of Radio Electronics, Kharkiv, Ukraine

    T. Romanova

  5. V. M. Glushkov Institute of Cybernetics, National Academy of Sciences of Ukraine, Kyiv, Ukraine

    P. Stetsyuk

Authors
  1. Yu. Stoyan
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  2. O. Pankratov
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  3. I. Lemishka
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  4. Z. Duriagina
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  5. J. Bennell
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  6. T. Romanova
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  7. P. Stetsyuk
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Corresponding author

Correspondence to Yu. Stoyan.

Additional information

The study was supported by the National Research Foundation of Ukraine (Grant #2020.02/167), Volkswagen Foundation (Grant #97775), and British Academy (Grant #100072).

Translated from Kibernetyka ta Systemnyi Analiz, No. 3, May–June, 2024, pp. 97–108; DOI https://doi.org/10.34229/KCA2522-9664.24.3.9.

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Stoyan, Y., Pankratov, O., Lemishka, I. et al. Simulation of 3D Volume Filling with Non-Spherical and Spherical Titanium Alloy Powder Particles for Additive Manufacturing. Cybern Syst Anal 60, 422–432 (2024). https://doi.org/10.1007/s10559-024-00683-6

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  • DOI: https://doi.org/10.1007/s10559-024-00683-6

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