AM-FEMU: An optimization method for additive manufacturing simulation parameters based on finite element model updating, utilizing three-dimensional deformation and melt pool temperature fields

Accurate model parameters are crucial for reliable metal additive manufacturing (AM) simulations, which are essential for understanding AM material formation mechanisms, designing AM components, and controlling manufacturing processes. This study addresses the discrepancy between AM simulations and experimental results by developing an Additive Manufacturing Finite Element Model Updating (AM-FEMU) method. The AM-FEMU method updates and optimizes the simulation parameters based on the temperature field of the melt pool and the deformation field of the substrate during the AM process. Online measurements of three-dimensional displacement and melt pool temperature were conducted using three-dimensional sampling moiré and multi-spectral colorimetric temperature measurement technologies. By comparing these measurements with finite element (FE) simulation, the heat source parameters and thermal expansion coefficient were updated successfully. Verification tests confirmed that the updated parameters significantly improved the accuracy of residual stress in AM simulations compared to the original parameters. This method promotes the application of FEMU in metal AM simulations, further providing a deeper understanding of the physical mechanism in metal AM process.