Development of an Initial FEM Framework to Model Particle-Substrate Contact in Fluidized Bed Finishing of L-PBF Parts

This work introduces an initial finite element (FE) framework for modelling particle-substrate interaction during fluidized bed surface finishing of Laser Powder Bed Fusion (L-PBF) components. Due to the complexity of as-built surface morphology and the difficulty of experimentally observing high-speed particle impacts, the mechanisms governing material removal remain poorly understood. The proposed 3D explicit FE model simulates the impact of stainless-steel particles on representative AlSi10Mg asperities using Johnson-Cook plasticity model and damage formulations. Results show that erosion occurs mainly through localized brittle-like detachment rather than extensive plastic deformation. Sequential impacts and oblique trajectories significantly increase internal energy absorption, enhancing asperity fragmentation and the surface smoothing level. The framework provides a foundation for future optimization of Fluidized Bed Finishing (FBF) parameters for improved finishing of additively manufactured metal parts.