Michael Gouge

Michael Gouge
Autodesk Inc. · Project Pan

Doctor of Mechanical Engineering

About

17
Publications
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633
Citations

Publications

Publications (17)
Article
Thermal management is a critical issue for Selective Laser Sintering (SLS) of polymers, as the thermal history within the powder bed has a significant impact on the produced part quality. Numerical simulations can calculate the thermal history of a build, as well as residual stress, distortion, lack of fusion, and powder aging effects. Model parame...
Article
Thermo-mechanical finite element modeling of additive manufacturing processes, such as Directed Energy Deposition and Laser Powder Bed Fusion, has been widely applied for the prediction and mitigation of part distortion. However, as the size of modeled geometries gets larger, the number of nodes and elements required in the finite element mesh incr...
Article
Numerical simulation has been posited as a key tool to reduce the unwanted distortion which occurs during laser powder bed fusion additive manufacturing, yet the scale and speed of the process makes traditional moving source modeling impractical. In this work a part-scale model is validated for the distortion modeling of laser powder bed fusion man...
Article
Thermal modeling of additive manufacturing processes such as Laser Powder Bed Fusion is able to calculate a thermal history of a build. This simulated thermal history can in turn be used as an input to further simulate temperature related characteristics such as residual stress, distortion, microstructure, lack of fusion porosity, and hot spots. In...
Chapter
This chapter outlines the methodology to numerically solve the equations which describe the thermal and mechanical equations for AM processes. This discussion follows that used by the Netfabb Simulation tool which was used to complete the FE validation studies in the rest of the book. However, the modeling approach is general, and may be applied to...
Chapter
The thermo-mechanical modeling of laser powder bed fusion processes using traditional moving source methods is impractical due to the requirements for both spatial and temporal discretization of the problem according to good finite element practice. To circumvent these limitations, multi-scale methods have been attempted. This work utilizes a multi...
Chapter
This chapter introduces the topic of additive manufacturing simulation. The motivation for modeling AM processes and mitigating build failure without costly iterative experiments is detailed. A short survey of modeling literature for welding, directed energy deposition, and powder bed fusion processes is made. A list of the primary challenges in th...
Article
A three-dimensional finite element model is developed to allow for the prediction of temperature, residual stress, and distortion in multi-layer Laser Powder-Bed Fusion builds. Undesirable residual stress and distortion caused by thermal gradients are a common source of failure in AM builds. A non-linear thermoelastoplastic model is combined with a...
Article
In situ experimental measurements of the laser powder bed fusion build process are completed with the goal gaining insight into the evolution of distortion in the powder bed fusion build process. Utilizing a novel enclosed instrumented system, five experimental builds are performed. Experimental builds compare materials: Ti-6Al-4V and Inconel® 718,...
Article
Experimental measurements are a critical component of model development, as they are needed to validate the accuracy of the model predictions. Currently, there is a deficiency in the availability of experimental data for laser powder bed fusion made parts. Here, two experimental builds of cylindrical geometry, one using a rotating scan pattern and...
Article
There has been continuing effort in developing analytical, numerical, and empirical models of laser-based additive manufacturing (AM) processes in the literature. However, advanced physics-based models that can be directly used for feedback control design, i.e., control-oriented models, are severely lacking. In this paper, we develop a physics-base...
Article
Fixturing of components during laser cladding can incur significant conductive thermal losses. However, due to the surface roughness at contact, interfacial conduction is impeded. The effective contact conductivity, known as gap conductance, is much lower than the contacting material conductivities. This work investigates modeling conduction losses...
Article
The selection of the feedstock material form significantly affects the temperature and resulting distortion generated during laser cladding. An experimental investigation is undertaken to characterize the differences in temperature and deformation histories resulting from laser cladding using powder and wire. While both feedstock produce good quali...
Article
A comprehensive methodology for the implementation of thermal convection into the finite element (FE) analysis of laser direct energy deposition (DED) cladding is developed and validated. Improved convection modeling will produce improved thermal simulations, which will in turn yield more accurate results from subsequent models seeking to predict m...

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