Methodology for element selection and clustering in multi-axis directed energy deposition simulation

Specific modeling techniques are necessary to accurately capture the physical mechanisms for simulating the macroscale thermo-mechanical behavior of an additive directed energy deposition (DED) process. When using the finite element method (FEM) to simulate the DED process, the material deposition typically requires the activation of grouped elements along the deposition path. G-code-based software interfaces usually handle the element grouping (clustering) procedure according to the planned deposition path. However, modern robotic systems often use individualized proprietary controller languages for DED, meaning no generic G-code is available for simulation. A concept that handles the element grouping mechanism without relying on G-code is proposed. The method uses a standardized neutral tool path information from the computer aided manufacturing (CAM) system to automate element grouping. This study demonstrates and analyzes the generally applicable approach for modeling a multi-axis deposition process. The implementation of pre-processing in the FEM as well as the mathematical formulations and methods required for automated element selection and grouping are described.