Discrete element method model calibration and validation for the spreading step of the powder bed fusion process to predict the quality of the layer surface

A Discrete Element Method model, including interparticle cohesive forces, was calibrated and validated to develop a tool to predict the powder layer’s quality in the powder bed fusion process. An elastic contact model was used to describe cohesive interparticle interactions. The surface energy of the model particles was estimated by assuming that the pull-off force should provide the strength of the material evaluated at low consolidation with shear test experiments. The particle rolling friction was calibrated considering the bulk density of the layer produced by the spreading tool. The model was validated with the experiments by comparing the wavelet power spectra obtained with the simulations with those of the experimental layers illuminated by grazing light. The calibration proposed in this study demonstrated superior performance compared to our previous methods, which relied on measuring the angle of repose and unconfined yield strength. • A model according to discrete element model was developed to simulate the powder spreading in the powder bed fusion process. • Surface energy of the model particles was estimated from powder shear testing experiments. • Particle rolling friction was calibrated considering the bulk density of the layer. • Image analysis was used to compare experimental and simulated powder layers. • The model was validated by comparing the model and the experimental wavelet power spectra of the surface.