CN108984984B - Method for analyzing influence of ultrasonic impact treatment on residual stress of laser selective melting forming metal component - Google Patents
Method for analyzing influence of ultrasonic impact treatment on residual stress of laser selective melting forming metal component Download PDFInfo
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- CN108984984B CN108984984B CN201811031831.XA CN201811031831A CN108984984B CN 108984984 B CN108984984 B CN 108984984B CN 201811031831 A CN201811031831 A CN 201811031831A CN 108984984 B CN108984984 B CN 108984984B
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Abstract
The invention belongs to the field of additive manufacturing, and particularly relates to an analysis method for influence of ultrasonic impact treatment on residual stress of a metal component formed by selective laser melting; the method comprises the steps of firstly simulating the melting and forming process of the aluminum alloy sheet in the selective laser area by adopting finite element software Simufact. The invention utilizes the Msc.Marc power transient module to carry out ultrasonic impact simulation, takes the melting forming stress field of the laser selected area as the initial condition, and the calculation result is well consistent with the measuring result of the residual stress tester in the aspects of numerical value and change trend, thereby realizing the purposes of optimizing impact process parameters and researching the action mechanism of the impact process parameters.
Description
Technical Field
The invention belongs to the field of additive manufacturing, and particularly relates to an analysis method for influence of ultrasonic impact treatment on residual stress of a metal component formed by selective laser melting.
Background
The aluminum alloy has the advantages of good mechanical property and processability, small density, good corrosion resistance and wear resistance, high strength and rigidity, strong impact resistance and the like, and is widely applied to the fields of aerospace, automobile manufacturing, ships and ocean engineering equipment. The selective laser melting and forming mode can manufacture components with any shapes without the limitation of the structural complexity of parts. In recent years, the laser selective melting forming technology of aluminum alloy parts is increasingly applied.
Due to the characteristic that the selective laser melting forming processing mode continuously and rapidly melts and solidifies in the processing process, residual stress and deformation are easily generated after processing. For the aluminum alloy component, the rigidity is lower, so deformation, cracking and the like are easier to occur, and the application of the selective laser melting forming technology to the manufacture of large-size components is seriously inhibited. Therefore, effective post-processing techniques are of great significance to control the residual stress of the component and to improve surface quality. The ultrasonic impact technology is used for processing the surface of a part in a high-frequency mechanical impact mode, converts the original tensile stress of the surface of the part into the compressive stress beneficial to a component, prolongs the fatigue life, and has the advantages of small equipment volume, simplicity in operation, strong applicability and the like. As an effective post-processing technique, it is widely used.
However, the ultrasonic impact process has a complicated mechanism, which makes it difficult to optimize the process parameters. The method of simply relying on experimental data and operation experience wastes a great amount of manpower, material resources and time.
At present, a plurality of experts and scholars perform simulation analysis work on the influence of ultrasonic impact on the residual stress in the component. There is little simulated analysis of ultrasonic impact for residual stress of laser selective melting additive manufactured components. This simulation analysis must be based on the residual stress and deformation of the laser-selective melt-formed component. Current simulation analysis generally does not consider the effects of initial stress and deformation. With respect to the simulation of the laser selective melt-forming of the macro-structure, specific additive manufacturing simulation software must be applied to be possible. The finite element software commonly used to simulate the ultrasound process at present are ANSYS/LS-DYNA/ABAQUS and Msc. But only the msc. marc can read in the residual stress field and deformation analyzed by the simulfact.
Disclosure of Invention
The invention aims to provide an analysis method for the influence of ultrasonic impact treatment on the residual stress of a molten metal component formed in a selective laser area, which can realize the purposes of optimizing impact process parameters and researching the action mechanism of the impact process parameters.
An analysis method for influence of ultrasonic impact treatment on residual stress of a metal component formed by selective laser melting comprises the following steps:
step 1: firstly, finite element software Simufact.Adtive is adopted to simulate the selective laser melting and forming process to obtain a residual stress field and deformation, and the residual stress field and the deformation are read into Simufact.Forming and cooled to room temperature to obtain a stable residual stress field and deformation.
And 2, reading a deformation geometric body in the Msc.Marc in a multi-step calculation mode, then reopening a file, setting the residual stress of the laser selective melting forming component as an initial condition according to nodes and grids, and then carrying out ultrasonic impact simulation analysis and calculation.
And 3, establishing an ultrasonic impact model in Msc.
The method for analyzing the influence of ultrasonic impact treatment on the residual stress of the molten and formed metal component in the selected laser area comprises the following steps in step 2:
step 2.1, simulating a selective laser melting forming process, namely reading a three-dimensional component model into Simdefect.
And 2.2, calculating in a transition step, introducing the stress field and the deformation geometry of the result file obtained by Simufact.Adtive calculation into Simufact.Forming, endowing the same material properties again, cooling to room temperature of 25 ℃, and obtaining the cooled stress field and the cooled result file of the deformation geometry model.
The method for analyzing the influence of ultrasonic impact treatment on the residual stress of the molten metal component formed in the selected laser area is characterized in that a corresponding rule of multiple impacts at the same position in MSC.
According to the method for analyzing the influence of ultrasonic impact treatment on the residual stress of the metal component formed by melting in the laser selection area, an implicit solver is adopted in the ultrasonic impact process.
The method for analyzing the influence of ultrasonic impact treatment on the residual stress of a metal component formed by selective laser melting is characterized in that a magnetostrictive or piezoelectric crystal transducer converts high-frequency alternating electric energy into mechanical energy, the vibration output end part of the transducer is connected with an amplitude transformer, a certain gap is formed between the other end part of the amplitude transformer and an impact needle, when the transducer is subjected to low-amplitude longitudinal reciprocating motion when the high-frequency alternating electric energy is input, the amplitude transformer amplifies the amplitude to impact the impact needle, the impact needle impacts the surface of a workpiece at a high speed and then rebounds, so that the amplitude transformer and the workpiece rapidly and repeatedly move for many times, the surface of the workpiece is treated, the original stress distribution of the workpiece is changed, and the beneficial pressure stress to the component is introduced.
The invention has the beneficial effects that:
the invention utilizes the Msc.Marc power transient module to carry out ultrasonic impact simulation, takes the melting forming stress field of the laser selected area as the initial condition, and the calculation result is well consistent with the measuring result of the residual stress tester in the aspects of numerical value and change trend, thereby realizing the purposes of optimizing impact process parameters and researching the action mechanism of the impact process parameters.
Drawings
FIG. 1 is a finite element mesh division of an impacted member;
FIG. 2 is an overall assembly view of the punch, the impact pin and the impacted member after meshing;
FIG. 3 is a graph of displacement load applied to a punch;
FIG. 4 is a cross-sectional view of the component after selective laser melting and forming along a longitudinal section of the centerline;
FIG. 5 is a cross-sectional view of the component after selective laser melting and forming, cut along a centerline longitudinal section and then distributed;
FIG. 6 is a transverse stress distribution of the post-impact treated component after being cut along a centerline longitudinal section;
FIG. 7 is a transverse displacement profile of the post-impact treated member taken along a centerline longitudinal section.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
FIG. 1 is a finite element mesh division of an impacted member; FIG. 2 is an overall assembly view of the punch, the impact pin and the impacted member after meshing; FIG. 3 is a graph of displacement load applied to a punch; FIG. 4 is a cross-sectional view of the component after selective laser melting and forming along a longitudinal section of the centerline; FIG. 5 is a cross-sectional view of the component after selective laser melting and forming, cut along a centerline longitudinal section and then distributed; FIG. 6 is a transverse stress distribution of the post-impact treated component after being cut along a centerline longitudinal section; FIG. 7 is a transverse displacement profile of the post-impact treated member taken along a centerline longitudinal section.
The first is a simulation of the selective laser melting process.
And 2, removing all supports after adding the support and cutting modes and setting calculation.
Step 3, setting processing parameters: laser power 200w, efficiency 50%, spot diameter 70um, scanning speed 1.8m/s, process layer thickness 0.03mm, and scanning strategy 670 per revolution.
And 4, dividing grids, wherein the unit size is 0.2 mm. Submitting calculation to obtain the residual stress field and the integral plastic strain.
And (5) simulating a cooling process.
And step 2, reapportioning the component AlSi10Mg material.
And 3, adding a cooling analysis step, setting the initial temperature of the component to be 50 ℃ and setting the ambient temperature to be 25 ℃.
And 4, submitting for analysis to obtain a result file of the stable integral plastic deformation geometric body with the stress field.
And carrying out numerical simulation on the influence of the ultrasonic impact on the laser selected area finite element residual stress field on the basis. The specific process is as follows:
and (3) dividing a finite element model and a grid: the finite element model comprises three parts of an impacted member, an impact pin and a punch. The mesh of the impacted component is directly led into the deformed mesh, the impacting needle and the punch are modeled according to actual sizes and are set as a deformed body, the impacting needle and the punch are subjected to mesh division by adopting a tetrahedral mesh, and the machined component which is read in the deformed mesh and the model of the impacting needle and the punch which are divided into the mesh are shown in figure 2.
Material properties: the impact pin is made of steel, and the properties of common Q235 steel, input density, elastic modulus and Poisson ratio are adopted; the punch is made of tungsten steel, and the properties of common YG28 steel are adopted to input density, elastic modulus and Poisson ratio; the member to be impacted was measured for its modulus of elasticity and poisson's ratio using a modulus of elasticity measuring instrument, and its density was measured. For the impacted member, the material property of the member is in consideration of work hardening, strain rate effect and temperature softening effect, because the action between the impact pin and the member belongs to a high-speed nonlinear collision process. The dynamic constitutive relation of AlSi10Mg is described by using a Johnson-cook model, wherein formula (r) is an expression of the model, reflects the influence of the factors on stress, and the model is set in MSC.
Sigma-stress, epsilon-plastic strain,
-a strain rate of the strain,
-reference strain rate, T-temperature, Tr reference temperature, Tm material melting point temperature. A. B, n, C and m-respectively represent initial yield strength, strain strengthening index, strain rate sensitivity coefficient, hardening index and temperature softening index.
Experiments herein show that a is 578Mpa, B is 1509Mpa, n is 0.928, C is 0.0375, m is 0.94, Tr is 298.15k, Tm is 933.15k,
contact setting; as the impacted component collides with the impacting needle and the punch in the impacting process, the impacted component is arranged to be in surface-to-surface contact with the impacting needle and the punch and the impacting needle on the two dynamic surfaces. The coefficient of friction between the striker pin and the test piece was set to 0.5.
Setting of loads and boundary conditions
And (3) establishing a displacement table in a table module, setting the residual stress of selective laser melting forming as a previous analysis state as an initial stress field, setting the established displacement table as a displacement boundary condition of the punch in the direction perpendicular to the impacted member, limiting all degrees of freedom of the impact pin except the impact motion direction, adding displacement constraint on a bottom node of the impacted member, and limiting the motion of the impacted member, as shown in fig. 3.
And establishing a dynamic transient analysis working condition.
Submitting analysis operation and post-processing: after the finite element calculation, the calculation results of the laser selective melting forming component processed by all ultrasonic impacts, including stress, displacement and the like, are obtained, and as shown in fig. 6 and 7, further processing can be carried out.
Compared with the experimental result, the method has good consistency. The invention is an accurate and effective simulation analysis method for ultrasonic impact treatment, and has important significance for optimizing ultrasonic impact process parameters and exploring the action mechanism of the ultrasonic impact process parameters.
The foregoing is an exemplary description of the invention and it should be noted that any simple modifications and variations or other equivalent substitutions which a person skilled in the art could make without inventive faculty fall within the scope of protection of the invention without departing from the core of the invention.
Claims (4)
1. An analysis method for influence of ultrasonic impact treatment on residual stress of a metal component formed by selective laser melting is characterized by comprising the following steps:
step 1, firstly, simulating a selective laser melting and forming process by adopting finite element software Simufact.Adtive to obtain a residual stress field and deformation, reading the residual stress field and the deformation into Simufact.Forming, and cooling the residual stress field and the deformation to room temperature to obtain a stable residual stress field and deformation;
step 2, reading a deformation geometry in Msc.Marc in a multi-step calculation mode, then reopening a file, setting the residual stress of the laser selective melting forming component as an initial condition according to nodes and grids, and then carrying out ultrasonic impact simulation analysis and calculation;
step 3, establishing an ultrasonic impact model in Msc.Marc software, then taking a stress field obtained by selective laser melting and forming as an initial state of analysis, and carrying out process simulation analysis on the action of ultrasonic impact on the residual stress field of the selective laser melting and forming metal component;
the step 2 specifically comprises the following steps:
step 2.1, simulating a selective laser melting forming process, namely reading a three-dimensional component model into Simufact.
And 2.2, performing multi-step calculation, namely introducing the stress field and the deformation geometry of the result file obtained by Simufact.Adtive calculation into Simufact.Forming, endowing the same material properties again, performing cooling treatment, cooling to room temperature of 25 ℃, and obtaining the result file of the cooled stress field and deformation geometry model.
2. The method for analyzing the influence of ultrasonic impact treatment on the residual stress of the laser selective melting forming metal component according to claim 1, wherein the method comprises the following steps: the corresponding rule of multiple impacts at the same position in the MSC and Marc simulation and the full coverage impact in the real experiment is established according to the moving speed of the ultrasonic impact equipment in the experiment.
3. The method for analyzing the influence of ultrasonic impact treatment on the residual stress of the laser selective melting forming metal component according to claim 1, wherein the method comprises the following steps: the ultrasonic impact process adopts an implicit solver.
4. The method for analyzing the influence of ultrasonic impact treatment on the residual stress of the laser selective melting forming metal component according to claim 1, wherein the method comprises the following steps: the basic principle of the ultrasonic impact technology is that a magnetostrictive or piezoelectric crystal transducer converts high-frequency alternating electric energy into mechanical energy, the vibration output end part of the transducer is connected with an amplitude transformer, a certain gap is reserved between the other end part of the amplitude transformer and an impact needle, when the transducer carries out small-amplitude longitudinal reciprocating motion when the high-frequency alternating electric energy is input, the amplitude transformer amplifies the amplitude to impact the impact needle, so that the impact needle impacts forwards at a high speed and rebounds after impacting the surface of a workpiece, so that the amplitude transformer and the workpiece rapidly and repeatedly move for many times, the surface of the workpiece is treated, the original stress distribution is changed, and the pressure stress beneficial to a member is introduced.
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| CN109735843B (en) * | 2019-03-21 | 2021-06-29 | 株洲辉锐增材制造技术有限公司 | Process method for increasing thickness of laser cladding high-hardness alloy layer and laser cladding repaired product thereof |
| CN111687553A (en) * | 2020-05-28 | 2020-09-22 | 西安交通大学 | Method for improving residual stress distribution of electric arc additive manufacturing structural part through ultrasonic impact |
| CN111625982B (en) * | 2020-05-29 | 2023-07-25 | 成都赫尔墨斯科技股份有限公司 | Ansys-based impact and drop impact analysis method for portable navigation equipment |
| CN112883518B (en) * | 2021-03-09 | 2023-05-26 | 西安石油大学 | Method for predicting residual stress and deformation of TIG (tungsten inert gas) additive and rolled composite manufactured part |
| CN113218875B (en) * | 2021-04-30 | 2023-03-21 | 东南大学 | Laser ultrasonic measurement method for residual stress of metal additive manufacturing part |
| CN114492113A (en) * | 2022-01-05 | 2022-05-13 | 南京航空航天大学 | Impact damage numerical simulation optimization method based on laser mapping entity grid |
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