Crystal Plasticity Thermo-Mechanical Simulation in Additive Manufacturing at Part-Scale using Texture Component Approach
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A thermo-mechanical framework based on a texture component crystal plasticity method is investigated to identify microstructural effects on parts produced by additive manufacturing (AM). In this approach, a coarse mesh is adopted for the crystal plasticity-based mechanical simulation, with each finite element comprising multiple grains. The texture component method accounts for the multi-grain distribution within each element. The crystal plasticity multi-grain method is first applied to representative volume elements (RVEs) and compared to a simple reduced grain approach [1] to identify the anisotropic mechanical behavior of grain structures with marked textures. Subsequently, thermo-mechanical AM process simulations are performed using the proposed multi-grain method, where a layer-by-layer method is implemented to simulate part construction and multi-grain activation [2]. The stress and distortion predictions from the texture component-based crystal plasticity model are compared with results from the isotropic and reduced grain methods to assess the efficiency of the numerical approaches.