AM PravaH: A multiphysics, multiscale Volume-of-Fluid & Lagrangian coupled simulation package for advanced manufacturing solutions
Dr. Rimzhim Gupta
R&D at Paanduv Applications | IISc | AMU | Women in 3D Printing Ambassador Bareilly Chapter | Bach Therapy Level-1
Paanduv Applications Private Limited, Bareilly, India
Software code that simulates processes used in advanced manufacturing such as L-PBF and W-LAM, the new version 2.0 is now made available to the industry.
Simulation. Optimization. Innovation
For over 3 years, Paanduv Applications Private Limited's research and development wing has been developing AM PravaH - a multiphysics and multiscale simulation software for solving complex physics of metal Additive Manufacturing processes. Until now - this is a unique code that simulates the process for 4-phase systems, i.e. solid, liquid, vapor, and shielding gas capturing the interfaces to the best possible accuracy. Nonetheless, consideration of the vapor phase as a separate phase captures the real effect of recoil pressure and the drag generated because of that. AM PravaH is available for industrial use in the market. It is smartly parallelized for scalable solutions and leverages HPC's capability. It is also equipped with the flexibility to adjust the Fidelity level considering the value of time and computational resources of the industry. Paanduv Applications is open to partnering with government and non-government research labs and R&D organizations to exploit the full potential of the software and if necessary, provide customized developments for them.
The development of AM PravaH started with the vision of 1 person and with a team of 2 people in a room in the summer season of 2021.
Technology advancement and growth
AM PravaH offers a Finite Volume approach to multiphysics thermal fluid modeling incorporating 4-phase multiphase flow for melt pool flow, heat transfer, phase change, Marangoni convection, recoil pressure for metal evaporation, particle modeling for spherical, and non-spherical powder spreading, and Discrete Tray Radiation Method for laser dynamics, and Fresnel reflections for elaborate defect prediction. The molten liquid is modeled as a Newtonian fluid with laminar flow. The software also includes the Monte - Carlo - Potts algorithm-based microstructure and grain evolution.
The software places a special emphasis on including the recoil pressure as the implication of adding vapor as the fourth phase and on Marangoni Convection and Fresnel Reflections in forming a melt pool in conduction, transition, and keyhole mode. These factors have a rather strong influence on the accuracy of the results generated using AM PravaH. With AM PraaH researchers can strategize to eliminate the bubble formation in a keyhole or minimize the defects by employing a reduced ambient pressure, shielding gas flow, and preheating the substrate either by low-energy laser or by uniform heating.
Complex scan patterns for scan strategy optimization, multilayer laser scans for porosity and surface roughness analysis, optimizing the design of experiments, and accomplishing 3/4th of them using AM PravaH can improve the pace at which the process parameters can be optimized.
The software can effectively capture defects generated due to vapor or inert gas entrapment such as porosity, and vapor plume ejection with the inclusion of recoil pressure effect and drag force in the mushy zone due to vapor generation. Other defects generated due to surface tension i.e. balling, humps & bulges, spattering, lack of fusion, and partial melting of powder, etc. are detected with AM PravaH.
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Powder spreading and achieving the correct packing density of particles can also be major causes of instant bubble formation and lead to near-surface defect formation. Hence, an accurate solution requires including the current topology of the previous layer for powder spreading. AM PravaH does that hence improving the accuracy by taking the real effects of void fractions and the interaction of particles and void with the laser and the effect generated because of that.
Now with AM PravaH, researchers, institutes, industries, and manufacturers interested in metal additive manufacturing to produce high-quality products and parts can learn from their simulated manufacturing processes and get insights into the effects of parameters on their products before a heavy investment is made on manufacturing resources and time.
Stepping stones in the journey
On this journey, we are fortunate to be trusted by our partners. The journey started with IIT Hyderabad being the first user of AM PravaH in 2021. Followed by multiple IITs, the Defense Organization of India, and premier institutes in Singapore and the USA.
We also collaborate with institutes to expand and align the development activities to newer areas where institutes can validate the models experimentally and include the added models for their publications and student thesis purposes. IIT Bhilai is our first collaborator. We are eager to partner and collaborate with research labs, startups, institutes, OEMs, and R&D organizations from India and Abroad. This is a value addition for AM machine manufacturers to integrate the process modeling and simulation software along with their machines to provide a complete package to the user.
AM PravaH was awarded as the “Best indigenously developed simulation software of the Year consecutively in 2023 & 2024 by IIT Bombay and IIT Delhi in association with 3D Graphy and recognized by IIM (Indian Institute of Metals) as the game changer in Additive Manufacturing industry in 2024.
Timeline
2021 - Paanduv begins developing AM PravaH; started with a 3-phase system; Launches AM PravaH v1.0; IIT Hyderabad becomes the first purchaser
2022 - Paanduv launches AM PravaH v1.2; adds Marangoni convection
2023 - Paanduv launches AM PravaH v1.5; dark-themed GUI, the 4-phase multiphase system with Fresnel reflections and Marangoni Convection; Paanduv ties hands with the University of North Texas and Texas A&M Qatar
2024 - Paanduv ties hands with DRDO, NUS, IIT Roorkee, IIT Dharwad and IIT Varanasi
2025 - Paanduv launches AM PravaH v2.0; with Wire - LAM modeling module, laser beam shaping, non-spherical particles, temperature-dependent thermophysical properties
AM PravaH comes for research and teaching licenses serving usability for different purposes i.e. for cutting edge research or for learning and training purposes.
People who want to collaborate with us on any projects, proposals, and new ideas, can reach out to us at support@paanduv.com or connect us through LinkedIn.
AM PravaH 2.0 is releasing soon in the early next year and an AM PravaH workshop will happen soon after.
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