The Effect of Geometries of Thin-Walled Parts on Residual Stresses and Deformations in SLM

Abstract

Selective Laser Melting (SLM) technology demonstrates unique advantages in manufacturing complex thin-walled structures for aerospace and medical device applications, yet residual stresses during the forming process significantly compromise part accuracy and performance. This study systematically investigated the influence of geometric features on stress distribution and deformation mechanisms in thin-walled parts using 316L stainless steel powder through experiments. Three representative structures - polygonal tubes, elliptical tubes, and conical tubes - were analyzed, revealing that: polygonal tubes exhibit stress concentration at edges, which can be effectively mitigated by rounded transitions; elliptical tubes demonstrate a critical curvature effect where moderate curvature variations enhance precision; and conical tubes with inward-tilted structures significantly reduce deformation by altering heat accumulation effects. These findings provide important theoretical guidance for structural optimization of SLM-fabricated thin-walled components.