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Error in stress model for multilayer deposition

Error in stress model for multilayer deposition

Error in stress model for multilayer deposition

(OP)
Hi:

I am doing a thermal and stress analysis for laser deposition using commercial software. My thermal analysis has convection, conduction, and radiation and no contact and gives temperature as output for the analysis. I use the temperature as load for my stress analysis where the mechanical prop such as yield stress at 0.2% plastic strain, elastic modulus poisson ratio are a function of temperature. The part is constrained in XYZ direction perpendicular to laser travel direction (the part in reality is constrained by vice). My simulation runs with no issue during deposition of layer 1 but as layer 2 first set of elements get activtated and reach their melting point the simulation aborts with the error: too many attempts made for the increment, also I see element set distorted. I use element birth/death technique and mesh is same for HT and stress analysis. Can someone please help, I have attached images of stress simulation in progress and page 5 shows the second layer element set activated and simulation aborted.

 http://files.engineering.com/getfile.aspx?folder=96288aa6-253e-46cf-bf38-502a5f7f2b02&file=initial_results.docx

Thanks,
P   

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