CN106709176A - Dynamic numerical simulation technology for laser melting deposition formed molten pool - Google Patents

Dynamic numerical simulation technology for laser melting deposition formed molten pool Download PDF

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Publication number
CN106709176A
CN106709176A CN201611169129.0A CN201611169129A CN106709176A CN 106709176 A CN106709176 A CN 106709176A CN 201611169129 A CN201611169129 A CN 201611169129A CN 106709176 A CN106709176 A CN 106709176A
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model
rho
numerical simulation
laser melting
molten bath
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邢本东
王向明
胡宗浩
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Shenyang Aircraft Design and Research Institute Aviation Industry of China AVIC
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Shenyang Aircraft Design and Research Institute Aviation Industry of China AVIC
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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2111/00—Details relating to CAD techniques
    • G06F2111/10—Numerical modelling
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
    • G06F2119/06—Power analysis or power optimisation

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  • General Engineering & Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • Laser Beam Processing (AREA)

Abstract

The invention relates to a dynamic numerical simulation technology for a laser melting deposition formed molten pool. The technology comprises the steps that (1) a numerical model is established, and a grid is divided; (2) model properties and material properties are set; (3) a heat source model is selected; (4) boundary conditions are set; (5) a solver is selected; (6) model initialization is performed; and (7) a temperature filed, a velocity field and molten pool morphology are calculated. According to a calculation model provided in the dynamic numerical simulation technology for the laser melting deposition formed molten pool, a free surface and a mushy zone of the molten pool are considered, and the calculated molten pool morphology, temperature field, velocity filed and free surface are more approximate to truth.

Description

A kind of Laser Melting Deposition shapes molten bath dynamic numerical simulation technology
Technical field
The invention belongs to increases material manufacturing technology field, more particularly to a kind of Laser Melting Deposition shaping molten bath dynamics numerical value Analogy method.
Background technology
Laser Melting Deposition forming technique is the advanced manufacturing technology for growing up the nineties in 20th century, can be realized The manufacture of high-performance labyrinth metal parts.Laser Melting Deposition forming technique is to combine laser melting coating and rapid prototype manufacturing Technology and the new technology without mold freedom near-net-shape that is formed, are particularly suitable for high-performance labyrinth difficult-to-machine metal part Quick manufacture.
Laser Melting Deposition shaping principle be：First according to part C AD models, by the 3D data of part according to certain thickness Degree section turns into a series of 2D outline datas.According to 2D outline datas, successively fusing metal substrate forms molten bath to laser beam, and Constantly to injecting powder in molten bath, powder is into melting and solidify to form cladding layer behind molten bath.So, by heap from level to level Product, ultimately forms 3D parts.The technology is not restricted by work metal design of part complexity substantially, can quickly be manufactured Go out metal parts or mould with overhung structure, the complicated complicated shape such as cavity and interior discharge orifice road, and the part for shaping Only need a small amount of following process.
Laser Melting Deposition shaping is an extremely complex Physical Metallurgy process.Flow behavior in molten bath, will determine Mass transfer, heat transfer, the phase transformation in molten bath, and molten bath dimensional profile.Laboratory facilities are difficult the flowing of capture bath and melt Deeply convince breath.
The content of the invention
It is an object of the invention to provide a kind of Laser Melting Deposition shaping molten bath Numerical Simulation On The Dynamics, for studying Technological parameter and pool size profile, temperature field, the relation in flow field.
To reach above-mentioned purpose, the technical solution adopted by the present invention is：A kind of Laser Melting Deposition shapes molten bath dynamics Numerical simulation technology, including
(1) numerical model and grid division are set up, numerical model includes base material and air-shed and carries out mesh generation to it；
(2) model attributes and material properties are set
Gas-liquid two-phase flow model is set up using the VOF models in Fluent；Using the Melting And Solidification modeling of Fluent Phase transition process；The thermal physical property parameter that will be varied with temperature, is loaded into model by writing UDF programs；
(3) heat source model is selected
Thermal source is distributed as body heat source form, specially
In formula, q (r) is the heat flow density at source center r, and η is laser power utilization rate, and Q is laser power, R light Spot radius, ZgsRefer to model in Z-direction size of mesh opening；
(4) boundary condition is set
Boundary condition includes air layer, substrate upper surface, base material left and right side and bottom surface；
Air layer：Left and right side and top, are defined as pressure export；
Substrate upper surface：There is the energy input of Gauss thermal source, and heat convection is acted on heat loss through radiation.These embody In the source item of energy equation, formula is
In formula, k thermal conductivity factors, the distance of r and spot center, R spot radius, η is laser power utilization rate, and Q is laser Power, htConvection transfer rate, σ Boltzmann constants, εrBlackbody coefficient, TaAmbient temperature；
Base material left and right side and bottom surface：There is heat convection and heat loss through radiation with surrounding air；
(5) solver is selected
Pressure-velocity couple solution program uses PISO, the discrete use PRESTO of pressure field, the equation of momentum, energy equation Using Second Order Upwind；
(6) model initialization
Using Region command definition substrate regions, model initialization setting is carried out by path, body portion is set 1 region is equal to for metal phase volume fraction.
(7) temperature field, velocity field and Pool are calculated.
Temperature field of molten pool, velocity field and Pool are calculated using fixed mesh method, governing equation group is：
In formula, ρ is density, and U is flowing velocity in molten bath, u, v be U in x, the component of y both directions, h is sensible enthalpy, and α is Thermal diffusivity, μ is dynamic viscosity coefficient, and P is pressure, ShIt is energy equation source item, Sx,SyIt is x, momentum side in y both directions The source item of journey；
In formula, the △ H latent heats of fusion, f1Liquid phase fraction, AmushMushy zone constant, ε=0.001.
Further, in step one, base material is less than base material with the grid of air-shed contact portion and the grid of air-shed The grid at other positions.
Further, mushy zone constant keeps acquiescence in the Melting And Solidification modeling phase transition process of the Fluent of step 2 Value 105。
Further, in step 2, the thermal physical property parameter includes specific heat, the coefficient of heat conduction, kinematic viscosity, surface tension Coefficient etc..
Further, convection transfer rate h need to be amplified when step 4 is calculatedt。
Further, in step 5, time step takes 5 × 10-6Second.
The computation model that Laser Melting Deposition shaping molten bath Numerical Simulation On The Dynamics of the invention are proposed considers molten Pond Free Surface and mushy zone, the Pool for calculating, temperature field, velocity field, Free Surface are closer to truth.
Brief description of the drawings
Accompanying drawing herein is merged in specification and constitutes the part of this specification, shows and meets implementation of the invention Example, and be used to explain principle of the invention together with specification.
Fig. 1 is model of the invention and mesh generation.
Fig. 2 is the thermal physical property parameter for varying with temperature of the invention.
Fig. 3 is the solution of the present invention flow chart.
Specific embodiment
To make the purpose, technical scheme and advantage of present invention implementation clearer, below in conjunction with the embodiment of the present invention Accompanying drawing, the technical scheme in the embodiment of the present invention is further described in more detail.In the accompanying drawings, identical from start to finish or class As label represent same or similar element or the element with same or like function.Described embodiment is the present invention A part of embodiment, rather than whole embodiments.Embodiment below with reference to Description of Drawings is exemplary type, it is intended to used It is of the invention in explaining, and be not considered as limiting the invention.Based on the embodiment in the present invention, ordinary skill people The every other embodiment that member is obtained under the premise of the work of creation type is not made, belongs to the scope of protection of the invention.Under Face is described in detail with reference to accompanying drawing to embodiments of the invention.
In the description of the invention, it is to be understood that term " " center ", " longitudinal direction ", " transverse direction ", "front", "rear", The orientation or position relationship of the instruction such as "left", "right", " vertical ", " level ", " top ", " bottom ", " interior ", " outward " are based on accompanying drawing institute The orientation or position relationship for showing, are for only for ease of the description present invention and simplify description, rather than the dress for indicating or implying meaning Put or element with specific orientation, with specific azimuth configuration and operation, therefore it is not intended that must be protected to the present invention The limitation of scope.
The flow chart that Laser Melting Deposition of the invention shapes molten bath Numerical Simulation On The Dynamics is illustrated in figure 3, its Including
(1) numerical model and grid division are set up
The numerical model of foundation is as shown in figure 1, size is：40mm × 22mm, its middle and lower part represents base material 40mm × 20mm, Top represents air-shed 40mm × 2mm (black line lower section is base material, and top is air).In view of air-shed and base material melting end Divide and there is heat convection, grid needs local cypher, and size of mesh opening is：0.05mm × 0.05mm (Y >=18.5mm), remainder Size of mesh opening gradually increases.
(2) model attributes and material properties are set
Gas-liquid two-phase flow model is set up using the VOF models in FLUENT；Using the Melting And Solidification modeling of FLUENT Phase transition process, mushy zone constant keeps default value 105.The thermal physical property parameter that consideration is varied with temperature, including specific heat, heat transfer system Number, kinematic viscosity, surface tension coefficient etc., and be loaded into model by writing UDF programs.The hot physical property ginseng for varying with temperature Number is shown in Fig. 2.
(3) heat source model is selected
Thermal source distribution approximately uses Gaussian function
In formula, q (r) is the heat flow density at source center r, and η is laser power utilization rate, and Q is laser power, and R is Spot radius.
Herein, heat source model is plane heat source, acts on molten bath Free Surface.Due in FLUENT softwares, energy equation source Item is with body heat source-representation, so needing for plane heat source distribution to be rewritten into body heat source form.
In formula, ZgsRefer to model in Z-direction size of mesh opening, here ZgsIt is 0.001m.
(4) boundary condition is set
Boundary condition includes air layer, substrate upper surface, base material left and right side and bottom surface.
Air layer：Left and right side and top, are defined as pressure export.
Substrate upper surface：There is the energy input of Gauss thermal source, and heat convection is acted on heat loss through radiation.These embody In the source item of energy equation.
In formula, k is thermal conductivity factor, and r is the distance with spot center, and R is spot radius, and η is laser power utilization rate, Q It is laser power, htIt is convection transfer rate, σ is Boltzmann constant, εrIt is blackbody coefficient, TaIt is ambient temperature.
Base material left and right side and bottom surface：There is heat convection and heat loss through radiation with surrounding air.Because base material is remote in model Less than actual size, heat exchange efficiency is caused to be much smaller than actual heat exchange efficiency.It is thus appropriate to amplify convection transfer rate, in this implementation 200 are set in example.
(5) solver is selected
Method for solving sets as follows：Pressure-velocity couple solution program uses PISO, the discrete use PRESTO of pressure field, The equation of momentum, energy equation use Second Order Upwind, and time step takes 5 × 10-6Second.
(6) model initialization
Using Region command definition substrate regions, model initialization setting is carried out by path, body portion is set 1 region is equal to for metal phase volume fraction.
(7) temperature field, velocity field and Pool are calculated
Laser melting process is one has the convection-diffusion effect Phase-change Problems of moving boundary.Proposed using V.R.VOLLER The fixed mesh method of solution Phase-change Problems calculate temperature field of molten pool, velocity field and Pool.Governing equation group is：
In formula, ρ is density, is flowing velocity in molten bath, u, v be U in x, the component of y both directions, h is sensible enthalpy, and α is heat Diffusivity, μ is dynamic viscosity coefficient, and P is pressure, ShIt is energy equation source item, Sx、SyIt is x, the equation of momentum in y both directions Source item.
In formula, Δ H is the latent heat of fusion, flIt is liquid phase fraction, AmushIt is mushy zone constant, ε=0.001.
Beneficial effects of the present invention：
The present invention is discussed in detail using the dynamic (dynamical) method in FLUENT softwares simulated laser melt deposition forming process molten bath, To seek pool size profile, temperature field and evolution of flow field rule.
In existing molten bath dynamics simulation, weld pool surface is assumed to be plane, or even ignores convection action in molten bath, and The computation model proposed in the present invention considers molten bath Free Surface and mushy zone, Pool, temperature field, the speed for calculating , Free Surface is closer to truth.
The above, optimal specific embodiment only of the invention, but protection scope of the present invention is not limited thereto, Any one skilled in the art the invention discloses technical scope in, the change or replacement that can be readily occurred in, Should all be included within the scope of the present invention.Therefore, protection scope of the present invention should be with the protection model of the claim Enclose and be defined.

Claims (6)

1. a kind of Laser Melting Deposition shapes molten bath dynamic numerical simulation technology, it is characterised in that including
(1) numerical model and grid division are set up, numerical model includes base material and air-shed and carries out mesh generation to it；
(2) model attributes and material properties are set
Gas-liquid two-phase flow model is set up using the VOF models in Fluent；Using the Melting And Solidification modeling phase transformation of Fluent Process；The thermal physical property parameter that will be varied with temperature, is loaded into model by writing UDF programs；
(3) heat source model is selected
Thermal source is distributed as body heat source form, specially
S q ( r ) = 3 η Q πR 2 exp ( - 3 r 2 R 2 ) / Z g s
In formula, q (r) is the heat flow density at source center r, and η is laser power utilization rate, and Q is laser power, R hot spots half Footpath, ZgsRefer to model in Z-direction size of mesh opening；
(4) boundary condition is set
Boundary condition includes air layer, substrate upper surface, base material left and right side and bottom surface；
Air layer：Left and right side and top, are defined as pressure export；
Substrate upper surface：There is the energy input of Gauss thermal source, and heat convection is acted on heat loss through radiation, these are embodied in energy Measure in the source item of equation, formula is
- k ∂ T ∂ y = 3 η Q πR 2 exp ( - 3 r 2 R 2 ) r ≤ R
- k ∂ T ∂ y = h t ( T - T a ) + σϵ r ( T 4 - T a 4 ) r > R
In formula, k thermal conductivity factors, the distance of r and spot center, R spot radius, η is laser power utilization rate, and Q is laser power, htConvection transfer rate, σ Boltzmann constants, εrBlackbody coefficient, TaAmbient temperature；
Base material left and right side and bottom surface：There is heat convection and heat loss through radiation with surrounding air；
(5) solver is selected
Pressure-velocity couple solution program uses PISO, the discrete use PRESTO of pressure field, the equation of momentum, energy equation to use Second Order Upwind；
(6) model initialization
Using Region command definition substrate regions, model initialization setting is carried out by path, body portion is set to gold The region that symbolic animal of the birth year volume fraction is equal to 1；
(7) temperature field, velocity field and Pool are calculated
Temperature field of molten pool, velocity field and Pool are calculated using fixed mesh method, governing equation group is：
∂ ρ ∂ t + d i v ( ρ U ) = 0
∂ ( ρ u ) ∂ t + d i v ( ρ U u ) = d i v ( μ g r a d u ) - ∂ P ∂ x + S x
∂ ( ρ v ) ∂ t + d i v ( ρ U v ) = d i v ( μ g r a d v ) - ∂ P ∂ y + S y
∂ ( ρ h ) ∂ t + d i v ( ρ U h ) = d i v ( α g r a d h ) + S h
In formula, ρ is density, and U is flowing velocity in molten bath, u, v be U in x, the component of y both directions, h is sensible enthalpy, and α is thermal expansion The rate of dissipating, μ is dynamic viscosity coefficient, and P is pressure, ShIt is energy equation source item, Sx,SyIt is x, the equation of momentum in y both directions Source item；
S h = ∂ ( ρ Δ H ) ∂ t + d i v ( ρ U Δ H )
S x S y = A m u s h ( 1 - f 1 ) 2 ( f 1 3 + ϵ ) u v
In formula, the △ H latent heats of fusion, f1Liquid phase fraction, AmushMushy zone constant, ε=0.001.
2. Laser Melting Deposition according to claim 1 shapes molten bath dynamic numerical simulation technology, it is characterised in that In step one, base material is less than the grid at other positions of base material with the grid of air-shed contact portion and the grid of air-shed.
3. Laser Melting Deposition according to claim 2 shapes molten bath dynamic numerical simulation technology, it is characterised in that step Mushy zone constant keeps default value 10 in the Melting And Solidification modeling phase transition process of rapid two Fluent5。
4. Laser Melting Deposition according to claim 3 shapes molten bath dynamic numerical simulation technology, it is characterised in that step In rapid two, the thermal physical property parameter is including specific heat, the coefficient of heat conduction, kinematic viscosity, surface tension coefficient etc..
5. Laser Melting Deposition according to claim 4 shapes molten bath dynamic numerical simulation technology, it is characterised in that step Rapid four need to amplify convection transfer rate h when calculatingt。
6. Laser Melting Deposition according to claim 5 shapes molten bath dynamic numerical simulation technology, it is characterised in that step In rapid five, time step takes 5 × 10-6Second.
CN201611169129.0A 2016-11-29 2016-12-16 Dynamic numerical simulation technology for laser melting deposition formed molten pool Pending CN106709176A (en)

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CN107609288A (en) * 2017-09-21 2018-01-19 中国科学院力学研究所 Computational methods of the molten drop to molten bath percussion in the electric arc combined welding of simulated laser
CN108197377A (en) * 2017-12-27 2018-06-22 中国石油化工股份有限公司江汉油田分公司勘探开发研究院 The critical flow calculation methodologies of gas-liquid two-phase throttling and device
CN108509665A (en) * 2017-02-27 2018-09-07 南京理工大学 The molten bath light intensity data field modeling method of photodiode detection
CN108680502A (en) * 2018-04-19 2018-10-19 广州德擎光学科技有限公司 The laser processing state monitoring device of multiphase feature is reconstructed based on spectrum constituency
CN109190260A (en) * 2018-09-07 2019-01-11 华中科技大学 A kind of laser-arc hybrid welding in industry Three dimensional transient simulation method
CN109460578A (en) * 2018-10-12 2019-03-12 山东理工大学 A kind of Mathematical Modeling Methods under non-real effect of centrifugal force
CN110070919A (en) * 2019-04-12 2019-07-30 上海交通大学 It is a kind of to be related to the melting model and its method for numerical simulation of crystal phase reaction
CN110075562A (en) * 2019-04-22 2019-08-02 天津大学 A kind of design method of the clarification structure of crystallizer
CN110625307A (en) * 2019-09-26 2019-12-31 华中科技大学 Method, device and equipment for predicting multilayer multi-channel stacking behavior of fuse additive manufacturing
CN110705158A (en) * 2019-09-26 2020-01-17 华中科技大学 Prediction method, device and equipment for gas-liquid-solid three-phase behavior of selective laser melting
CN111062121A (en) * 2019-11-29 2020-04-24 西北工业大学 Powder melting numerical simulation method based on height function-lattice boltzmann method
CN111112621A (en) * 2020-01-22 2020-05-08 南京理工大学 Method for predicting and monitoring shape and size of laser directional energy deposition molten pool
CN111168067A (en) * 2020-01-22 2020-05-19 南京理工大学 Pore prediction and control method based on laser directional energy deposition
CN111199098A (en) * 2019-12-25 2020-05-26 西安交通大学 Numerical simulation method for temperature field in SLM (Selective laser melting) forming process
CN111822828A (en) * 2020-06-16 2020-10-27 南京航空航天大学 Electric arc additive forming prediction modeling method based on molten drop transition
CN112307689A (en) * 2020-11-09 2021-02-02 辽宁忠旺机械设备制造有限公司 Method for calculating temperature of molten pool of heat accumulating type aluminum melting furnace
CN113139314A (en) * 2021-04-29 2021-07-20 四川大学 Heat source numerical simulation method for laser additive manufacturing process

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CN108509665A (en) * 2017-02-27 2018-09-07 南京理工大学 The molten bath light intensity data field modeling method of photodiode detection
CN108509665B (en) * 2017-02-27 2020-03-06 南京理工大学 Method for modeling light intensity data field of molten pool detected by photodiode
CN107609288A (en) * 2017-09-21 2018-01-19 中国科学院力学研究所 Computational methods of the molten drop to molten bath percussion in the electric arc combined welding of simulated laser
CN107609288B (en) * 2017-09-21 2019-12-03 中国科学院力学研究所 Calculation method of the molten drop to molten bath percussion in the electric arc combined welding of simulated laser
CN108197377A (en) * 2017-12-27 2018-06-22 中国石油化工股份有限公司江汉油田分公司勘探开发研究院 The critical flow calculation methodologies of gas-liquid two-phase throttling and device
CN108197377B (en) * 2017-12-27 2021-08-03 中国石油化工股份有限公司 Gas-liquid two-phase throttling critical flow calculation method and device
CN108680502A (en) * 2018-04-19 2018-10-19 广州德擎光学科技有限公司 The laser processing state monitoring device of multiphase feature is reconstructed based on spectrum constituency
CN108680502B (en) * 2018-04-19 2020-09-04 广州德擎光学科技有限公司 Laser processing state monitoring device based on spectrum selection region reconstruction multiphase characteristics
CN109190260A (en) * 2018-09-07 2019-01-11 华中科技大学 A kind of laser-arc hybrid welding in industry Three dimensional transient simulation method
CN109460578A (en) * 2018-10-12 2019-03-12 山东理工大学 A kind of Mathematical Modeling Methods under non-real effect of centrifugal force
CN109460578B (en) * 2018-10-12 2023-07-04 山东理工大学 Mathematical modeling method under action of non-true centrifugal force field
CN110070919A (en) * 2019-04-12 2019-07-30 上海交通大学 It is a kind of to be related to the melting model and its method for numerical simulation of crystal phase reaction
CN110070919B (en) * 2019-04-12 2023-02-17 上海交通大学 Melting model related to crystalline phase reaction and numerical simulation method thereof
CN110075562A (en) * 2019-04-22 2019-08-02 天津大学 A kind of design method of the clarification structure of crystallizer
CN110705158A (en) * 2019-09-26 2020-01-17 华中科技大学 Prediction method, device and equipment for gas-liquid-solid three-phase behavior of selective laser melting
CN110625307A (en) * 2019-09-26 2019-12-31 华中科技大学 Method, device and equipment for predicting multilayer multi-channel stacking behavior of fuse additive manufacturing
CN111062121A (en) * 2019-11-29 2020-04-24 西北工业大学 Powder melting numerical simulation method based on height function-lattice boltzmann method
CN111199098A (en) * 2019-12-25 2020-05-26 西安交通大学 Numerical simulation method for temperature field in SLM (Selective laser melting) forming process
CN111199098B (en) * 2019-12-25 2022-02-11 西安交通大学 Numerical simulation method for temperature field in SLM (Selective laser melting) forming process
CN111168067A (en) * 2020-01-22 2020-05-19 南京理工大学 Pore prediction and control method based on laser directional energy deposition
CN111112621A (en) * 2020-01-22 2020-05-08 南京理工大学 Method for predicting and monitoring shape and size of laser directional energy deposition molten pool
CN111822828A (en) * 2020-06-16 2020-10-27 南京航空航天大学 Electric arc additive forming prediction modeling method based on molten drop transition
CN112307689A (en) * 2020-11-09 2021-02-02 辽宁忠旺机械设备制造有限公司 Method for calculating temperature of molten pool of heat accumulating type aluminum melting furnace
CN113139314A (en) * 2021-04-29 2021-07-20 四川大学 Heat source numerical simulation method for laser additive manufacturing process

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Application publication date: 20170524