High-Fidelity Multiphysics Simulation Framework for Analyzing the Coupled Effects of Thermal, Mechanical, and Electromagnetic Fields in Advanced Manufacturing Processes

Abstract

Advanced manufacturing processes, particularly in metal additive manufacturing (AM), laser-based machining, and electric discharge techniques, involve the simultaneous interaction of thermal, mechanical, and electromagnetic (EM) fields. Accurately modeling these coupled phenomena is critical for predicting microstructural evolution, residual stress formation, and overall part integrity. This paper presents a high-fidelity multiphysics simulation framework capable of capturing these interactions in a unified computational environment. Using finite element-based methods with adaptive meshing, the framework demonstrates predictive accuracy in simulating laser additive manufacturing of Inconel 718. Results show the critical influence of EM field-induced Lorentz forces on melt pool dynamics and thermal gradients.