Modelling of selective laser melting process with adaptive remeshing

Selective laser melting involves manufacturing of a part layer-by-layer by localised melting and solidification of metal powders. The geometry, composition, structure and property of the solidified deposit are significantly influenced by repeated exposure to the laser beam at a high scanning speed. A computationally efficient heat transfer model of selective laser melting is reported here using the finite element method with adaptive remeshing. The model has incorporated a very fine mesh, moving with the laser beam, to capture the local thermal gradient in and around the melt pool. A gradually varying coarser mesh is used away from the melt pool. The computed results are verified with that calculated using a uniform fine mesh and against reported experimental observations.