Parametric Thermal-Structural Analysis of Laser Material Processing

Project Overview

This project utilized ANSYS Workbench for a one-way coupled thermal-structural finite element analysis to simulate laser material processing. A transient heat transfer model applied a time-varying Gaussian surface heat flux, accounting for both continuous and pulsed laser operation and modeling convective cooling effects. The resulting temperature fields, incorporating temperature-dependent material properties, were then imported into a structural model to predict thermally induced stresses, plastic deformation, and overall structural response. A comprehensive parametric study explored the impact of various process parameters on key output metrics such as peak surface temperature, recast layer formation, and principal stress distributions. This methodology demonstrated the capability to predict complex material behavior under extreme thermal loads and identify process parameter sensitivities for different material types, providing valuable insights for advanced manufacturing process optimization and material selection.