Content

The lecture deals with state-of-the-art approaches in the physics-based modeling and simulation of additive manufacturing processes, with a strong connection to current research activities in this field. The focus is on modeling aspects of solid thermomechanics in the additive manufacturing of metals, such as the modeling of temperature evolution, microstructure, residual stresses, and thermal distortion. The lecture begins with an overview of the different classes of additive manufacturing processes. It then introduces the underlying physical mechanisms (for example, the causes of thermally induced residual stresses) as well as the relevant spatial and temporal scales in additive manufacturing. Next, current modeling approaches are presented, the resulting model equations are derived, and the application range, transferability, and limitations of these models are discussed in detail. In the following part of the course, methods for discretizing and numerically solving these model equations are introduced. In addition to the prediction accuracy of these computer-based modeling approaches, the computational cost is also a central topic of discussion. In this context, modern approaches to efficient code implementation are presented. These are crucial for enabling thermo-mechanical predictions at the scale of practically relevant component sizes.