dissimilarities in melt pool dimension

[amanullah17]

I am trying to simulate the LDED process and using Goldak heat source. the inp file is attached herewith. I have used the following as input :

**Material Deposition
*PARAMETER
beadWidth = 4.5
beadHeight = 1
**
*TABLE COLLECTION, NAME="ABQ_AM.MaterialDeposition"
*PARAMETER TABLE, TYPE= "ABQ_AM_MaterialDeposition"
"LDED.PrintHeadDepositionTrajectory","Bead"
**
*PARAMETER TABLE, TYPE= "ABQ_AM_MaterialDeposition_Bead"
"Z", <beadHeight>, <beadWidth>, 0.,"Below"
**
*PARAMETER TABLE, TYPE= "ABQ_AM_MaterialDeposition_Advanced"
"Full",0.0,0.0,0.01,,,
**------------------------------------------------
**Moving heat source
*PARAMETER
laserSpotRadius = 2.4
penetrationDepth = 1.2
GoldakParamA = laserSpotRadius
GoldakParamB = penetrationDepth
GoldakParamCF = laserSpotRadius
GoldakParamCR = laserSpotRadius
GoldakParamFF = 2*(GoldakParamCF)/(GoldakParamCR+GoldakParamCF)
GoldakParamFR = 2*(GoldakParamCR)/(GoldakParamCR+GoldakParamCF)


but in simulation I am not getting the same dimension in the melt pool. I have used the temperature limit 25 (lowest) and 1405(highest) to represent the melt pool.

 

[FEA way]

but in simulation I am not getting the same dimension in the melt pool

What's the difference ? How do you measure it ? And how is it related to the mesh size ?

 

[amanullah17]

What's the difference ? How do you measure it ? And how is it related to the mesh size ?

In the AM modeler,
I have used the value of "a" of goldak heat source model = laser spot radius (2.4mm). so, 2a =4.8mm which is bigger than the bead width (4.5 mm).
But in simulation, the melt pool width is less than 4.5 mm. Same thing is happened for other dimensions as well. Simulated depth is less than the input "b" value (1.2mm).
Please see the images for reference