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In order to predict the more accurate shape information of the melt pool inSelective Laser Melting (SLM), a new finite element temperature fieldsimulations model is proposed. The simulations use a new heat source model thattakes into account the influence of the powder layout, the surface of thesubstrate and the changes in the thickness of the powder layer after fusion onthe energy distribution. In order to construct this new heat source model,firstly an improved optimization method based on the gradient descent and theunivariate search technique is proposed to simulate the powder layout, and thenthe laser beam propagation between the powder and the surface of the substrateis tracked and recorded to obtain the energy distribution. Finally, accordingto the distribution of laser energy between the powder layer and the surface ofthe substrate, the heat source model is divided into two parts: one is thesurface of substrate heat source model being the Gaussian distribution, theother one is the powder layer heat source model-satisfying the Gaussiandistribution on the horizontal plane, changes in the depth direction accordingto the functional relationship obtained by the fitting. In addition, thethickness change of the powder layer after fusion is analyzed, and is takeninto account in the heat source model. The powder simulation results arecompared with the powder scattering experiment results to verify theeffectiveness of the powder model. Comparing the temperature field simulationwith the experiment, the results show that the predicted molten pool widthrelative error is 6.4%, and the connect width error is 9.6%, which has betteraccuracy and verifies the validity of the temperature field simulation model.

A new heat source model for selective laser melting simulations based on energy distribution on the powder layer and the surface of substrate