1) This document summarizes research on modeling and experimentally validating sintering phenomena in additive manufacturing processes like selective laser sintering (SLS). 2) Using ANSYS simulations, the document models heat transfer during the SLS process for different materials like steel, nickel, and titanium to analyze temperature evolution. 3) The research aims to validate computational SLS models by comparing simulations to experiments conducted on an EOS M280 3D printer and analyze how SLS processes are affected by different materials like various grades of steel.

1. SINTERING PHENOMENA IN ADDITIVE MANUFACTURING PROCESS:
MODELING AND EXPERIMENTAL VALIDATION
Philip Byrd1, David Bustamante1, Yeoh Jia Seng1, Linlin Cai1
Lih Yiing Then1, Weng Hoh Lee1, Youssef Abdulshahid1
Jing Zhang2, Yi Zhang2
Purdue School of Engineering and Technology,
Indiana University-Purdue University Indianapolis
Abstract Review of Literature Current Status of Research
Methods
• By using the ANSYS to work on the
movement of heat souse, the result had
applied three different material
properties, which is steel, nickel and
titanium.
• Objects printed with SLS are made with
powder materials, most commonly
plastics, such as nylon, which are
dispersed in a thin layer on top of the
build platform inside an SLS machine.
• A laser, which is controlled by a computer
that tells it what object to "print," pulses
down on the platform, tracing a cross-
section of the object onto the powder
Introduction
• Selective laser sintering (SLS) is a powder-
based layer-additive manufacturing
process generally meant for rapid
prototyping and rapid tooling
• Laser beams in continuous or pulse mode
are used as a heat source for scanning and
joining powders in predetermined sizes
and shapes of layers
• Geometry of the scanned layers
corresponds to the various cross sections
of the computer-aided design (CAD)
models or stereolithography (STL) files of
the object
• Computer aided design (CAD) model is
mathematically sliced into thin layers. The
object is then created by selectively fusing
sequentially deposited layers of a powder
with a scanning laser beam
References
"3D FE Simulation for Temperature Evolution in the Selective Laser Sintering Process." 3D FE Simulation
for Temperature Evolution in the Selective Laser Sintering Process. N.p., n.d. Web. 17 Oct. 2013.
Karapatis, N.P., J.P.S. van Griethuysen, and R. Glardon. “Direct Rapid Tooling: AReview of
Current Research.” Rapid Prototyping Journal 4, no. 2 (June 1998): 77–
89.doi:10.1108/13552549810210248.
"Three-dimensional Transient finite Element Analysis of the Selective Laser Sintering Process." N.p., 25
Feb. 2007. Web.
Automation Creations, Inc.. (2009). MatWeb, Overview of materials for AISI 4000 Series
Steel,http://www.matweb.com/search/DataSheet.aspx?MatGUID=210fcd12132049d0a3e0cabe7d091eef&
ckck=1. Retrieved at July 14, 2015.
1Department of Mechanical Engineering, 2Richard G. Lugar Center for Renewable Energy, 3Department of Mechanical Engineering Technology
• Over the last few decades, additive
manufacturing process provides more
representative user’s ideas from the range
of elegant home projects to highly
complex prototypes. The most common
method of the metal sintering is the
selective laser sintering (SLS)
• Using ANSYS, the animation of the SLS
heat flow has been captured and being
compared and contrast based on types of
materials
• The computational models of SLS additive
manufacturing will be validated and
calibrated based on the EOS M280 3D
printer
• Sintering Analysis Load steps
• SLS Process Associate with Various
Differences of AISIS 4000 Steel Series
• SLS Process Associate with Different
types of Materials
• Three-dimensional (3-D) printing is an
additive printing process. The original
technology is based on ink-jet principles
and can print with a variety of materials
• The modelling of the SLS process
included (1) the interactions between the
laser beam and the powder bed surface,
(2) the heat transfer mechanisms in the
powder and the solid parts of the
material, (3) the phase transformation of
the material from the powder state to
the solid state by the sintering process
Thermal loadsteps on the sintering plate with different motion of sintering
including linear motion and ‘3D’ motion.
Thermal Conductivity Specific Heat Capacity
Density
Conclusions
• The result of steel and nickel look similar
after applied the code of “3d-loadsteps”
• In the future, computational models of SLS
additive manufacturing will be validated
and calibrated based on EOS M280 3D
printer
Selective Laser Sintering (SLS)
Heat Movement of Laser Analysis using ANSYS
Selective Laser Sintering Process
Table of AISI 4000 Series Steel Physical Properties