Simulation and Validation of Transition Fillet Optimization for SLM-formed Arch Overhang Structures

LI Boyang; LIU Qiang; CHEN Yi; HU Wanqian; HUANG Yongde

doi:10.3969/j.issn.1674-6457.2025.09.012

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (9) : 126-135. DOI: 10.3969/j.issn.1674-6457.2025.09.012

Additive Manufacturing

Simulation and Validation of Transition Fillet Optimization for SLM-formed Arch Overhang Structures

LI Boyang^1,2, LIU Qiang¹, CHEN Yi¹, HU Wanqian³, HUANG Yongde^1,*

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Abstract

The work aims to develop a simulation model for selective laser melting (SLM) formed arch overhang structures and analyze the specific effects of the transition fillet R on the deformation and stress fields of SLM-formed specimens by changing the size of R. In this study, the Simufact Additive was utilized to simulate the unsupported arch overhang structure of SLM-formed high-strength aluminum alloy. The distribution characteristics of deformation and stress concentration regions of SLM-formed specimens were analyzed. Concurrently, the effect of the transition fillet R on the magnitude of deformation and stress values was examined. The measurement results of the actual specimens were compared to verify the reliability of the simulation. The deformation field distribution underwent alterations both prior to and following specimen removal from the substrate. Prior to removal, the regions exhibiting the most significant deformation were located at the periphery of the bottom contact area with the substrate. The magnitude of deformation exhibited a decrease in proportion to the increase in R, from 0.322 millimeters at R=4 mm to 0.277 millimeters at R=8 mm. The simulated trend of deformation alterations demonstrated a concurrence with the actual measured values. With respect to the stress field, it was observed that the distribution of stress field was analogous to the deformation field prior to specimen removal from the substrate. Following the removal, residual stresses in the bottom outer region and the horizontal region were released. However, substantial stresses persisted in the rounded corner region. The temperature field exhibited notable variations. At the center of the rounded corner region (at 1/2R), the temperature reached a maximum of 483 ℃ at R=4 mm and a minimum of 420 ℃ at R=8 mm after the formation of three layers. It was evident that increasing R enhanced the heat concentration in the rounded corner region. According to the established relationship among temperature, field stress and field strain, the selection of unsupported arch overhang structure parts should prioritize a larger transition fillet R. The deformation of the removed parts is predominantly attributed to the release of tensile stresses on the outer side of the bottom contact area with the substrate, as well as on the lower side of the horizontal overhang area.

Key words

selective laser melting / overhang structures / finite element simulation / transition fillet / residual stresses

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LI Boyang, LIU Qiang, CHEN Yi, HU Wanqian, HUANG Yongde. Simulation and Validation of Transition Fillet Optimization for SLM-formed Arch Overhang Structures[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 126-135 https://doi.org/10.3969/j.issn.1674-6457.2025.09.012

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