CN108038266A - A kind of method for numerical simulation of selective laser repair process - Google Patents
A kind of method for numerical simulation of selective laser repair process Download PDFInfo
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Abstract
The invention discloses a kind of method for numerical simulation of selective laser repair process：The first step：Repair foundation and the FEM meshing of part and area's 3-D geometric model to be repaired；Second step：Determine repair way Wiring technology parameter；The required floor height of restoring area is determined by repairing area's pattern, repairs road number, laser optimal power parameter and electric current width parameter；3rd step：The pre-treatment of restoring area dusty material parameter, the foundation of heat source loading environment；4th step：Heat-Source Parameters are defined, final temperature field is tried to achieve using life and death Strain Method；5th step：Calculate residual stress field；6th step：According to the result of calculation of stress distribution, judge whether the maximum equivalent of restoring area reaches the allowable stress of dusty material.The method for numerical simulation of the present invention, can optimize renovation technique parameter, improve part by one-step repair rate, reduce the deformation produced due to thermal stress.
Description
Technical field
The invention belongs to laser printing technology field, and in particular to a kind of numerical simulation side of selective laser repair process
Method.
Background technology
Laser powder feeding prosthetic appliance is by 400W-YAG lasers, three coordinate numerical control table, NC tables, powder transport control system etc.
Composition, laser powder feeding reparation is a kind of new technique for rapidly repairing, and as the novel process of increasing material manufacturing industry, it processes former
Reason meets discrete-accumulation forming principle.Its Principles is using laser emitter as manufactured energy, is controlled using computer sharp
Light beam by predetermined speed and adjusts suitable laser energy parameter to rapidoprint (metal dust) cladding path, and according to
The 2-D data information for repairing area's cross section profile carries out laser sintered, layer upon layer, polished again part after reparation,
A series of post-processing operations such as sandblasting can obtain part.It is that a kind of accurate repair is returned to work compared with traditional Bead weld repair
Skill, its reparation defect is few (heat affected area is small), it is played very important effect in aerospace field part reparation.
In aerospace field, due to the accuracy of laser repair process, high efficiency, by more and more technical staff
It is of interest.Although relative to traditional welding, its processing efficiency and quality have improved very much, in its repair process, due to
Laser power is larger, cooldown rate is fast, inevitably causes heat input should caused by concentrating when repairing more precision component
Power is distributed unbalanced, and then causes the deformation of repair member, secondary cracks source even occurs.
The content of the invention
It is an object of the invention to provide a kind of method for numerical simulation of selective laser repair process, can optimize and repair work
Skill parameter, improved part by one-step repair rate, reduce the deformation produced due to thermal stress.
The technical solution adopted in the present invention is a kind of method for numerical simulation of selective laser repair process, specific bag
Include following steps：
The first step：Establish and repair part and area's 3-D geometric model to be repaired, have to the 3-D geometric model of foundation
The first mesh generation of limit；
Second step：After the completion for the treatment of the first step, by repair area's pattern determine floor height needed for restoring area, repair road number,
Laser optimal power parameter and electric current width parameter；
3rd step：After the completion for the treatment of second step, pre-treatment is carried out to repairing part and repairing area's dusty material parameter, and establish
Heat source loading environment；
4th step：After the completion for the treatment of second step and the 3rd step, Heat-Source Parameters are defined, and are tried to achieve using life and death Strain Method
Final temperature field；
5th step：On the basis of the 4th step tries to achieve the temperature field of 3-D geometric model, solved using indirect method and repair knot
Entirely part is repaired after beam and repairs the residual stress field in area；
6th step：According to the result of calculation of the 5th step stress distribution, whether the maximum equivalent for judging to repair area reaches
The allowable stress of dusty material；If not up to, repairing will not crack under part theoretical condition；If reaching, part tool is repaired
There is the security risk cracked.
The features of the present invention also resides in：
The first step is specifically implemented in accordance with the following methods：
The 3-D geometric model for repairing part and area to be repaired is established in CAD software, and imports the sub- journey of CAE secondary development
In sequence, mesh generation is carried out to the 3-D geometric model established, mesh generation is divided using Local grid refinement method, most
Big size of mesh opening is not above setting size of mesh opening；
It is with encrypted all-hexahedral element mesh, i.e. hexahedral mesh unit size in the reparation heat affected area part in reparation area
0.01-0.008 times of the length of side of repairing model enveloping solid；Away from the region for repairing heat affected area, grid cell is used to add
The grid of 4-5 times of unit of close all-hexahedral element mesh；The unit grid of the part and its restoring area will be controlled in 0.5mm
Below.
In 3rd step：
For repair part and repair area's dusty material high temperature under thermal conductivity factor, heat emissivity coefficient, convection transfer rate,
Latent heat of phase change and the relevant nonlinear situation of heat content, are realized self-defined by the means of secondary development scripting；
Equations of Three-dimension is established to the 3-D geometric model in the first step, the initial strip of Equations of Three-dimension is set
Part, boundary condition；
It is that both double ellipse heat source functions, Gaussian function integrate to choose heat source calculation formula；
Internal body heat source is double-ellipsoid heat source, formula specific as follows：
In formula (1)：fwFor the weight of each ellipsoid；Q is the heat of input；A, b, c are heat source model ellipsoid major and minor axis, height
The size of degree；
Outer surface heat source selects the distribution of Gauss heat source：
In formula (2)：Q is input heat；R is the effective heating radius of laser；R is length of the required point to heating radius center
Degree.
In 4th step：In double ellipsoid Heat Conduction Differential Equations and Gauss heat source governing equation calculation procedure, by laser repairing
Pre-treatment gridding threedimensional model in temperature field is imported in finite element analysis secondary development program, conditions setting, overall to use
Life-and-death element iteration and fitting method, after the completion of each repair, carries out kill unit, then result of calculation is folded to preceding layer
Add, whole flow process is emulated by parameterizing scripting programming language, finally draws the temperature field of whole repair process.
5th step solves the process of residual stress field using the python language of CAE secondary development software scripts, utilizes
Python language calculates output result.
The beneficial effects of the present invention are：
(1) method for numerical simulation of the invention, carries out laser repair process residual stress based on CAE simulation softwares pre-
Survey, come part and its restoring area residual stress field under comparative analysis different parameters by varying different renovation technique parameters,
So as to which Instructing manufacture determines best repair technological parameter；
(2) method for numerical simulation of the invention, analysis cost are low；By to part in repair process due to residual stress mistake
Crackle that is big and producing is predicted, and can not only save human and material resources to greatest extent, additionally it is possible to analyze laser repair process
The regularity of distribution of middle residual stress, therefore efficiency is higher and accuracy is high.
Brief description of the drawings
Fig. 1 is blade and its restoring area threedimensional model schematic diagram in the embodiment of the present invention；
Fig. 2 is blade and its restoring area FEM meshing schematic diagram in the embodiment of the present invention；
Fig. 3 is the transient state temperature field cloud charts during laser repairing area in the embodiment of the present invention；
Fig. 4 is that end rear blade always equivalent residual stress field cloud charts are repaired in area to be repaired in the embodiment of the present invention.
(artwork of Fig. 1~Fig. 4 is cromogram).
Embodiment
The present invention is described in detail with reference to the accompanying drawings and detailed description.
A kind of method for numerical simulation of selective laser repair process of the present invention, comprises the following steps：
The first step：Establish and repair part and area's 3-D geometric model to be repaired, have to the 3-D geometric model of foundation
The first mesh generation of limit；
The 3-D geometric model for repairing part and area to be repaired is established in CAD software, and imports the sub- journey of CAE secondary development
In sequence, mesh generation is carried out to the 3-D geometric model established, mesh generation is divided using Local grid refinement method, most
Big size of mesh opening is not above setting size of mesh opening；
Repair process is that a heating is very uneven, Complete heart block transient process, the temperature of repairing remelt pool area
Graded is very big, and when grid division does not take uniform grid generally with original part, but in the reparation hot shadow for repairing area
Ringing area part, (hexahedral mesh unit size is the 0.01- of the length of side of repairing model enveloping solid with encrypted all-hexahedral element mesh
0.008 times), away from the region repaired, energy transmission is slow, and temperature distribution gradients change is relatively small, can use relatively dilute
Thin unit grid (grid cell is 4-5 times of close quarters unit)；In short, while keeping precision with computation rate
The total quantity of grid should be reduced.In the present invention involved part and and its restoring area unit grid to control 0.5mm with
Under.
Second step：After the completion for the treatment of the first step, by repair area's pattern determine floor height needed for restoring area, repair road number,
Laser optimal power parameter, electric current pulsewidth and voltage process parameter, that is, determine to repair the technological parameter in route；
3rd step：After the completion for the treatment of second step, pre-treatment is carried out to repairing part and repairing area's dusty material parameter, and establish
Heat source loading environment；
For repair part and repair area's dusty material high temperature under thermal conductivity factor, heat emissivity coefficient, convection transfer rate,
The relevant nonlinear situation of latent heat of phase change and heat enthalpy value, is realized self-defined by the means of secondary development scripting；
Equations of Three-dimension is established to the 3-D geometric model in the first step, the initial strip of Equations of Three-dimension is set
Part, boundary condition；
4th step：After the completion for the treatment of second step and the 3rd step, Heat-Source Parameters are defined, and are tried to achieve using life and death Strain Method
Final temperature field；
According in second step determine renovation technique parameter and the 3rd step defined in convection transfer rate, heat radiation system
Number, the heat analysis boundary condition of thermal conductivity factor, obtain finite element input parameter, wherein using newton-Laplce's method meter
Equations of Three-dimension is calculated, considers time loading analysis step, is applied in each grid node difference of 3-D geometric model position high
During this heat source, by the temperature T changed over time in repair process, that is, the temperature field of 3-D geometric model is obtained.
5th step：On the basis of the 4th step tries to achieve the temperature field of 3-D geometric model, solved using indirect method and repair knot
Entirely part is repaired after beam and repairs the residual stress field in area；
The whole process for solving residual stress field uses the python language of CAE secondary development software scripts, utilizes
Python language calculates output result.
6th step：Whether the maximum equivalent for judging restoring area according to the result of calculation of stress distribution reaches powder material
The allowable stress of material：If not up to, repairing will not crack under part theoretical condition；If reaching, repairing part has generation
The security risk of crackle.
Embodiment
The first step：A kind of Turbine Blade is established in three-dimensional software to repair part and repair the three-dimensional mould of zone groove
Type；Different trellis-types, the mesh generation of different dimension cells are carried out to repairing model overall region；Laser repairing and close to repairing
Multiple region (reparation heat affected area) uses fine and closely woven mesh generation, and (grid minimum unit is analyzed using full hexahedral element
0.1mm), not only improved compared with tetrahedron computational accuracy, but also the regularity of increasing material manufacturing can be embodied；Repair area and archetype
Remaining transitional region, size of mesh opening with repairing offset from increasing with constantly becoming larger, using tetrahedron and hexahedron hybrid grid
Divided, (divided based on hexahedron integral module algorithm, tetrahedral grid is added in its grid gap, four sides
The triangular apex of volume mesh is docked with nearest hexahedral mesh node) it is maximum no more than setting size of mesh opening
0.5mm；
Second step：Blade restoring area powder attribute is defined, carries out the heat that laser repairing area temperature field analysis must determine
Physical function parameter has：Thermal conductivity factor (W/m DEG C), convection transfer rate (W/m2DEG C), density (Kg/m3), specific heat (J/
Kg DEG C), fusing point (DEG C) and repair part initial temperature (DEG C)；Had to for Residual stresses and strains field stimulation definite
Thermo-physical performance parameters also have：Poisson's ratio, elasticity modulus (N/m2), the ginseng such as thermal coefficient of expansion (1/ DEG C) and yield limit (MPa)
Number；In the present embodiment, the initial temperature of blade is taken as 22 DEG C of room temperature；
Laser repairing computer simulation belongs to typical Complete heart block transient analysis, existing vaned many hot things
It is incomplete to manage parameter, particularly when high-temperature region is close to molten state or blank, such as：Thermal conductivity and specific heat capacity etc., although
It varies with temperature and changes, but due in laser repair process thermoplasticity cause strain generation, make its final analysis result
Closely related with process, the two direction varied with temperature is even opposite sometimes；To solve this problem, the present invention is in computer
Aid in inputting the thermo-physical performance parameters of representative temperature value in software, establish the engineering data base of parameter, it is secondary by scripting
Development language carries out the physical property and mechanical property parameters at interpolation method and the definite unknown temperatures of extrapolation iterative calculation；
3rd step：Apply heat source load；
Laser repair process is compared with traditional welding unlike powder bed melting, its heat source falls between, therefore this hair
It is bright that to attempt to choose heat source calculation formula be that both double ellipse heat source functions, Gaussian function integrate；
Internal body heat source is double-ellipsoid heat source, as follows：
In formula (1)：fwFor the weight of each ellipsoid；Q is the heat of input；A, b, c are heat source model ellipsoid major and minor axis, height
The size of degree；
Outer surface heat source selects the distribution of Gauss heat source：
In formula (2)：Q is input heat；R is the effective heating radius of laser；R is length of the required point to heating radius center
Degree；
4th step：Heat-Source Parameters are defined, final temperature field is tried to achieve using life and death Strain Method；
In double ellipsoid Heat Conduction Differential Equations and Gauss heat source governing equation calculation procedure, by laser repairing temperature field Qian Chu
Manage gridding threedimensional model to import in finite element analysis secondary development program, conditions setting is overall to change using Life-and-death element
For fitting process, after the completion of each repair, kill unit is carried out to preceding layer, then result of calculation is overlapped, whole flow process
Emulated by parameterizing scripting programming language, finally draw the temperature field of whole repair process；
5th step：Calculate residual stress field；
Result required by the 4th step temperature field of the present embodiment is used into indirect method, i.e., using Calculated Results of Temperature Field as stress field
The initial boundary conditions of input carry out solution calculating, so as to draw the remnants of model entirety after whole repair process and reparation
Stress field；Whole solution procedure uses the python language of CAE secondary development software scripts, can be accurate using python language
The output of each step is calculated as a result, specific method is as follows：
First, using finite element analysis software programming parametric design program (python language)；
Secondly, determine to repair area's condition and actual repair situation, should under the conditions of laser repairing speed be 1mm/s, laser work(
Rate 305w；Blade repairs the head of district 6.5mm, wide 2mm, thick 1.8mm, total to repair 110 layers of the number of plies；
Then, solution procedure is calculated into the temperature analysis in the 3rd step of the present embodiment, as Fig. 1 for blade and repairs area
Domain entirety threedimensional model (red area is restoring area), if Fig. 2 is blade FEM meshing, restoring area uses complete six
Face volume mesh is divided, and is emulated by univers parameter scripting programming language, calculates the temperature repaired during area
Field distribution (as shown in Figure 3), finally by indirect method (the initial boundary bar for inputting Calculated Results of Temperature Field as stress field
Part is calculated) the reparation end total residual stress distribution of rear blade (such as Fig. 4) is calculated, as seen from Figure 4, repair outer collar region
Since energy accumulating is more concentrated, internal stress is caused to increase, maximum equivalent reaches 672MPa, is not up to being permitted for dusty material
With stress, the hidden danger cracked is not had.
A kind of key point of the method for numerical simulation of laser repair process of the present invention is：
(1) physical function parameter of powder feeding dusty material, mechanical property are calculated by interpolation algorithm under different high temperature,
The selection of heat source calculation formula is integrated using both double ellipse heat source functions, Gaussian function and carries out analysis calculating；
(2) particularity of the distribution of the grid of laser repairing area and model entirety and grid cell division；
(3) Life-and-death element iterative method and discrete method are used, for balance between layers iteration, it is adaptive decline and when
Between step-length determine；
(4) residual stress for carrying out laser repairing area using two kinds of loadings for not having to heat source is predicted and analyzed.
Claims (5)
1. a kind of method for numerical simulation of selective laser repair process, it is characterised in that specifically comprise the following steps：
The first step：Establish and repair part and area's 3-D geometric model to be repaired, finite element is carried out to the 3-D geometric model of foundation
Mesh generation；
Second step：After the completion for the treatment of the first step, determine floor height needed for restoring area by repairing area's pattern, repair road number, laser
Optimal power parameter and electric current width parameter；
3rd step：After the completion for the treatment of second step, pre-treatment is carried out to repairing part and repairing area's dusty material parameter, and establish heat source
Loading environment；
4th step：After the completion for the treatment of second step and the 3rd step, Heat-Source Parameters are defined, and are tried to achieve finally using life and death Strain Method
Temperature field；
5th step：On the basis of the 4th step tries to achieve the temperature field of 3-D geometric model, solved using indirect method after repairing
The whole residual stress field repaired part and repair area；
6th step：According to the result of calculation of the 5th step stress distribution, whether the maximum equivalent for judging to repair area reaches powder
The allowable stress of material；If not up to, repairing will not crack under part theoretical condition；If reaching, repairing part has production
The security risk of raw crackle.
2. the method for numerical simulation of a kind of selective laser repair process according to claim 1, it is characterised in that described
The first step is specifically implemented in accordance with the following methods：
The 3-D geometric model for repairing part and area to be repaired is established in CAD software, and imports CAE secondary development subprograms
In, mesh generation is carried out to the 3-D geometric model established, mesh generation is divided using Local grid refinement method, maximum
Size of mesh opening is not above setting size of mesh opening；
Repair area reparation heat affected area part use encrypted all-hexahedral element mesh, i.e., hexahedral mesh unit size be reparation
0.01-0.008 times of the length of side of model enveloping solid；Away from the region for repairing heat affected area, grid cell is used to be encrypted
The grid of 4-5 times of unit of all-hexahedral element mesh；The unit grid of the part and its restoring area to control 0.5mm with
Under.
3. the method for numerical simulation of a kind of selective laser repair process according to claim 1, it is characterised in that described
In 3rd step：
For repairing the thermal conductivity factor under part and reparation area's dusty material high temperature, heat emissivity coefficient, convection transfer rate, phase transformation
Latent heat and the relevant nonlinear situation of heat content, are realized self-defined by the means of secondary development scripting；
Equations of Three-dimension is established to the 3-D geometric model in the first step, set Equations of Three-dimension primary condition,
Boundary condition；
It is that both double ellipse heat source functions, Gaussian function integrate to choose heat source calculation formula；
Internal body heat source is double-ellipsoid heat source, formula specific as follows：
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In formula (1)：fwFor the weight of each ellipsoid；Q is the heat of input；A, b, c are heat source model ellipsoid major and minor axis, height
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Outer surface heat source selects the distribution of Gauss heat source：
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4. the method for numerical simulation of a kind of selective laser repair process according to claim 3, it is characterised in that described
In 4th step：
In double ellipsoid Heat Conduction Differential Equations and Gauss heat source governing equation calculation procedure, by laser repairing temperature field pre-treatment net
Threedimensional model of formatting is imported in finite element analysis secondary development program, conditions setting, overall to be intended using Life-and-death element iteration
It is legal, after the completion of each repair, kill unit is carried out to preceding layer, then result of calculation is overlapped, whole flow process passes through
Parametrization scripting programming language is emulated, and finally draws the temperature field of whole repair process.
A kind of 5. method for numerical simulation of selective laser repair process according to claim 4, it is characterised in that：It is described
5th step solves the process of residual stress field using the python language of CAE secondary development software scripts, utilizes python languages
Speech calculates output result.
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| CN113139314B (en) * | 2021-04-29 | 2022-09-27 | 四川大学 | Heat source numerical simulation method for laser additive manufacturing process |
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| CN113343521B (en) * | 2021-05-27 | 2023-07-04 | 重庆大学 | Method for predicting interlayer thermal stress distribution in selective laser melting process based on COMSOL |
| CN113343521A (en) * | 2021-05-27 | 2021-09-03 | 重庆大学 | Method for predicting interlayer thermal stress distribution in selective laser melting process based on COMSOL |
| CN113962124A (en) * | 2021-10-20 | 2022-01-21 | 西安交通大学 | Laser-induced ultrasonic parameter optimization method and system |
| CN113962124B (en) * | 2021-10-20 | 2024-04-02 | 西安交通大学 | Laser-induced ultrasonic parameter optimization method and system |
| CN117454451A (en) * | 2023-10-26 | 2024-01-26 | 东北林业大学 | Temperature field numerical simulation method and system for laser sintering 3D printing process |
| CN117454451B (en) * | 2023-10-26 | 2024-05-10 | 东北林业大学 | Temperature field numerical simulation method and system for laser sintering 3D printing process |
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