Localized Hybrid Analytical-Finite-Element Thermal Modeling for Laser Powder Bed Fusion
Abstract
Hybrid analytical--finite-element methods support scan-resolved, part-scale thermal simulation of laser powder bed fusion, but their analytical evaluation cost grows as scan-line contributions accumulate. This work develops a space--time localized hybrid formulation that restricts where and how long each contribution is evaluated analytically. Residual terms and boundary conditions derived from the heat equation allow the finite-element correction to account for the thermal effect of contributions removed from the analytical field. The formulation is assessed using a single-line benchmark against an independent full finite-element solution and multiline comparisons with the conventional hybrid formulation. Localization limits the number of analytical contributions retained while maintaining close agreement with the conventional solution. A comparison with uncompensated temporal truncation demonstrates the importance of the residual correction in retaining the thermal effect of removed contributions. In the 500-line case, analytical and total simulation times are reduced by factors of approximately 25.5 and 3.92, respectively, with a relative nodal 2-norm difference of 0.139%.
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BibTeX
@misc{golafshani2026localized,
title = {{Localized Hybrid Analytical-Finite-Element Thermal Modeling for Laser Powder Bed Fusion}},
author = {Mohammad Amin Mohammadi Golafshani and Krishnan Suresh},
howpublished = {arXiv},
year = {2026},
month = oct,
doi = {10.48550/arxiv.2610.33273},
eprint = {2610.33273},
archivePrefix = {arXiv},
url = {https://arxiv.org/abs/2610.33273},
note = {CC BY 4.0},
}
RIS
TY - UNPB
TI - Localized Hybrid Analytical-Finite-Element Thermal Modeling for Laser Powder Bed Fusion
AU - Mohammad Amin Mohammadi Golafshani
AU - Krishnan Suresh
PY - 2026
DA - 2026/10/23
PB - arXiv
DO - 10.48550/arxiv.2610.33273
UR - https://arxiv.org/abs/2610.33273
AB - Hybrid analytical--finite-element methods support scan-resolved, part-scale thermal simulation of laser powder bed fusion, but their analytical evaluation cost grows as scan-line contributions accumulate. This work develops a space--time localized hybrid formulation that restricts where and how long each contribution is evaluated analytically. Residual terms and boundary conditions derived from the heat equation allow the finite-element correction to account for the thermal effect of contributions removed from the analytical field. The formulation is assessed using a single-line benchmark against an independent full finite-element solution and multiline comparisons with the conventional hybrid formulation. Localization limits the number of analytical contributions retained while maintaining close agreement with the conventional solution. A comparison with uncompensated temporal truncation demonstrates the importance of the residual correction in retaining the thermal effect of removed contributions. In the 500-line case, analytical and total simulation times are reduced by factors of approximately 25.5 and 3.92, respectively, with a relative nodal 2-norm difference of 0.139%.
ER -