Finite element modeling of residual stress and geometrical error formations in selective laser melting of metals

Recent works, both numerical and experimental, on residual stress and geometrical errors in selective laser melting-produced parts highlighted the preponderance of these phenomena. However, their mechanisms of appearance are not yet fully explained. An in-house finite element model was developed and implemented to reproduce their formations. The consistence of the model with existing simulation results and with respect to experimental observations was checked. Simulations were then performed using a computational design of experiments to better comprehend the underlying phenomena and the influence of the laser speed and power. Relationships between process parameters and residual stress, plastic strain, and geometrical errors formations have been put into evidence which can support optimization procedures at design stage.