CN109909502A - Online monitoring method of laser additive manufacturing process based on multi-source heterogeneous data - Google Patents

Online monitoring method of laser additive manufacturing process based on multi-source heterogeneous data Download PDF

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CN109909502A
CN109909502A CN201910204707.7A CN201910204707A CN109909502A CN 109909502 A CN109909502 A CN 109909502A CN 201910204707 A CN201910204707 A CN 201910204707A CN 109909502 A CN109909502 A CN 109909502A
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朱锟鹏
傅盈西
段现银
林昕
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Hefei Institutes of Physical Science of CAS
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Abstract

The invention discloses a kind of on-line monitoring method of laser gain material manufacturing process based on multi-source heterogeneous data, step includes: 1 to establish Laser beam energy distribution;2 obtain the speed of vibration of media;3 obtain the maximized surface temperature of powder bed;4 obtain the width in molten bath;The thermodynamical model of multi- scenarios method in 5 building laser melting process;The sparse coding of 6 multi-source heterogeneous data;7 obtain monitoring model online.The present invention can carry out real-time monitoring and process control in laser gain material manufacturing process, thus when there is tiny flaw with regard to adjust automatically technological parameter to eliminate defect, and then part forming quality is improved, meet actual precision and reliability requirement.

Description

The on-line monitoring method of laser gain material manufacturing process based on multi-source heterogeneous data
Technical field
The invention belongs to sensor and monitoring technical field, more specifically a kind of laser gain material system of big data driving Make on-line monitoring method.
Background technique
Increasing material manufacturing (3D printing/Quick-forming) technology is gradually changing people's traditional pattern of life and producer The features such as formula, customization rapid with its, digitlization and networking, is considered that the third time industrial revolution will be pushed.Laser gain material Manufacturing technology is current application range most one of wide, the maximum metal increasing material manufacturing technique of Practical significance, which utilizes high energy Laser beam is measured, according to scheduled path, fusing or sintering powder, then shaped after cooled and solidified, in labyrinth, free form surface There is significant advantage in the difficult processing part manufacturing such as thin-walled, such as high-performance complex component, biology manufacture in aerospace field Porous labyrinth manufacture and functionally graded material manufacture etc. in field.
However since laser gain material manufacturing process is with processes such as complicated physical chemistry, drip molding has biggish temperature The defects of gradient and thermal stress, forming process is easy to produce nodularization, hole, crackle, affects the precision and reliability of drip molding, The easily-deformable cracking of molded parts, lacks the process control of forming quality, seriously hinders the application of laser gain material manufacturing technology.
However, since the dynamic characteristic of laser gain material manufacturing process is complicated, sensor installation difficulty is high and related physical mistake Journey understands that the even reasons such as deficiency, real-time monitoring and the process control of laser gain material manufacturing process is not easy to carry out, and monitoring model has Limit, majority are modeled using infrared temperature information with processing quality.But temperature online measurement error is larger, and powder melts Or the mechanism of production of sintering process defect is complicated, only carries out mass measurement reliability deficiency with temperature information, correlative study still has Wait be pushed further into.
Although the post-processings such as sandblasting, heat treatment can obtain preferable surface smoothness and reduce fracture and lamination, Post-processing can bring the variation of part size, for internal structure complex parts, key functional domains and precision component etc., after The method of processing will be no longer applicable in.Therefore, realize that on-line monitoring, improvement forming quality more close in laser gain material manufacturing process Key.
Summary of the invention
The present invention is directed to the disadvantages mentioned above/or Improvement requirement of the prior art, provides a kind of based on multi-source heterogeneous data The on-line monitoring method of laser gain material manufacturing process, to can laser gain material manufacturing process carry out real-time monitoring with it is excessively program-controlled System, thus when there is tiny flaw with regard to adjust automatically technological parameter to eliminate defect, and then part forming quality is improved, meet Actual precision and reliability requirement.
To achieve the above object of the invention, the present invention adopts the following technical scheme:
A kind of the characteristics of on-line monitoring method of the laser gain material manufacturing process based on multi-source heterogeneous data of the present invention be by Following steps carry out:
Step 1 establishes the Laser beam energy distribution I (r) based on Gaussian Profile using formula (1):
In formula (1), r is distance of the point on laser facula to laser spot center, and ω is the radius of laser facula, and Φ is The central energy density of laser facula;
Step 2 obtains the speed u of vibration of media using formula (2):
In formula (2), α is absorptivity of the metal powder material to laser;γ is the adiabatic exponent of gas, ρ0For metal powder The density of material;
Step 3 obtains the maximized surface temperature T of powder bed using formula (3)m:
In formula (3), K is Boltzmann constant;K is the thermal coefficient of metal powder material;V is the molten of metal powder material Change speed;C is the hot melt ratio of metal powder material;
Step 4 obtains the width δ in molten bath using formula (4)w:
In formula (4), Δ HlvIt is metal powder material from solid-state to gaseous calorific potential;TlvIt is metal powder material from admittedly State is to gaseous equilibrium temperature;TslThe equilibrium temperature for being metal powder material from solid-state to liquid;
The thermodynamical model of multi- scenarios method in step 5, building laser melting process:
Step 5.1 is established using an apex angle of powder bed as origin O, with the two sides difference being connected with the origin O For X-axis and Y-axis, rectangular coordinate system O-XY is established;
Step 5.2 establishes temperature field finite element model in laser melting process using formula (5):
In formula (5), a is the thermal diffusivity of metal powder material, and T (t) is the transient temperature of t moment metal powder material, ▽2For Laplace operator;For the steady temperature field not changed over time, there are ▽2T (x, y, z)=0;T (x, y, z) be The temperature of metal powder material at point (x, y, z);
Step 5.3 obtains the temperature gradient in laser-irradiated domain along normal direction n using formula (6)
The sparse coding of step 6, multi-source heterogeneous data:
Step 6.1 does not obtain the multi-source heterogeneous data that temperature, sound and picture signal are constituted by sensor components, It is denoted as f;
Step 6.2 obtains transformed multi-source heterogeneous data to the multi-source heterogeneous data f progress Fast Fourier Transform (FFT) fT
Step 6.3, using redundant dictionary Φ to the transformed multi-source heterogeneous data fTIt is reconstructed, obtains formula (8) Shown in transformed multi-source heterogeneous data fTRarefaction representation, and pass through optimal l shown in formula (7)0Norm come constrain it is sparse because Sub- f 'TNumber:
s.t.fT=Φ f 'T,fT∈Rk (8)
In formula (8), RkIndicate the real number field of k dimension;Φf′TIt indicates the signal atom set obtained after sparse coding, and has: Indicate the l-th signal atom obtained after sparse coding;L indicates that signal is former Sub- number;
Step 7, to the signal atom set obtained after sparse codingCarry out Fusion Features Obtain observation sequence V={ v1,v2,...,vi,...,vn, viFor the observation data of i-th of visual layers;I=1,2 ..., n;N table Show the number of plies of visual layers;
Step 8 is obtained monitoring model online E (V, H | θ) using formula (8), and with the monitoring model online E (V, H | θ) Realize the on-line monitoring to laser gain material manufacturing process:
In formula (8), θ={ wij,ai,bjIt is parameter about RBM neural network model, wherein wijIndicate i-th it is visible The connection weight of layer and j-th of hidden layer, aiIndicate the biasing of i-th of visible layer, bjIndicate the biasing of j-th of hidden layer, hjIt indicates J-th of hidden layer;H indicates the set of hidden layer, and m indicates the number of plies of hidden layer.
Compared with the prior art, the beneficial effects of the present invention are embodied in:
1, the present invention probes into sound, temperature and figure in laser gain material manufacturing process with the methods of signal processing, image analysis As feature of the signal under different machining states, its relationship generated with defect in process is analyzed, laser gain material is disclosed The Physical Mechanism of manufacturing process;New metal powder is established to the absorbing model of laser light source, and laser melting process is carried out Thermodynamics emulation analyzes machined parameters to the affecting laws of processing temperature, to realize that the feedback control of the process provides research base Plinth;It is handled by source signal Fusion Features, improves the accuracy of the online quality-monitoring of process.To laser in the present invention The on-line monitoring of increasing material manufacturing forming process is also the core of research and development labyrinth metal parts high-precision high quality manufacturing equipment One of technology is therefore particularly suitable for metal increases material manufacturing technology in the applied field in the fields such as space flight, medical treatment and material manufacture It closes.
2, the present invention is based on the analyses to metal increasing material manufacturing forming physical process, in conjunction with the multi-modal of monitoring information itself Characteristic studies the consistency of the fusion of multi-source sensing data and multidimensional Heterogeneous Information expression in monitoring, utilizes the number of sparse decomposition Theory carries out sparse coding to foreign peoples' heat transfer agent such as temperature, sound, image, while realizing compression, the denoising to information With the character representation of consistency, excavated in multi-source heterogeneous data relevance, solve to multi-source heterogeneous information depth The basic premise practised and merged.
Specific embodiment
In the present embodiment, a kind of on-line monitoring method of the laser gain material manufacturing process based on multi-source heterogeneous data is by such as Lower step carries out:
During selective laser melting, laser and metal powder interaction generate fusing, gasification and the mistake rebuild Journey.There is multiple signal sources, including acoustical signal, plasmon signal, ultrasonic wave, infra-red radiation in this laser melting process With electric signal etc..The formation of these signals has tight association with variation and the formation and variation in molten bath, and Study of Laser melted Sound, temperature, image in journey, which are formed, and change mechanism is for the Thermodynamic Law for disclosing laser melting process important meaning Justice.
Sound, temperature, image in Study of Laser fusion process are formed and change mechanism, establishes laser using Gaussian Profile When Laser beam energy distribution, with establish disclose laser melting process Thermodynamic Law basis.
Step 1 establishes the Laser beam energy distribution I (r) based on Gaussian Profile using formula (1):
In formula (1), r is distance of the point on laser facula to laser spot center, and ω is the radius of laser facula, and Φ is The central energy density of laser facula;
Step 2 obtains the speed u of vibration of media using formula (2):
In formula (2), α is absorptivity of the metal powder material to laser;γ is the adiabatic exponent of gas, ρ0For metal powder The density of material;
Fuel factor can promptly occur due to absorbing high-power laser beam, surface temperature can rapidly rise to fusing temperature Degree.Maximized surface temperature TmIt can change with thermal coefficient k, the hot melt ratio c of burn-off rate v and material, so having:
Step 3 obtains the maximized surface temperature T of powder bed using formula (3)m:
In formula (3), K is Boltzmann constant;K is the thermal coefficient of metal powder material;V is the molten of metal powder material Change speed;C is the hot melt ratio of metal powder material;
Step 4 obtains the width δ in molten bath using formula (4)w:
In formula (4), Δ HlvIt is metal powder material from solid-state to gaseous calorific potential;TlvIt is metal powder material from admittedly State is to gaseous equilibrium temperature;TslThe equilibrium temperature for being metal powder material from solid-state to liquid;
The substances such as sound, temperature, the width and maximized surface temperature in the variation of image and molten bath and plasma fly Splash directly related, and the variation and the nodularization degree of selective laser melting part, hole in molten bath, temperature and plasma Rate, residual stress association.It is generated by the sound to selective laser melting, temperature, picture signal and is studied with change mechanism, looked for The key factor of selective laser melting part quality is influenced out and acquires key signal relevant to quality, to use more sensings Device monitors part quality on-line and provides reliable theoretical foundation.
The thermodynamical model of multi- scenarios method in step 5, building laser melting process:
The thermodynamics and dynamics analytic modell analytical model based on laser photocoagulation multi- scenarios method is established, is disclosed in powder evolutionary process Various phenomenons, such as hole formation, molten bath flowing, and propose a kind of new thinking, by based on physical process numerical model with Monitoring system based on multi-source data is mutually confirmed, and realizes more acurrate more reliable on-line monitoring.Laser is along the road Fen Xing Diameter is scanned on powder bed, and heat transfer process includes radiating, between the convection current and bisque and base station between bisque and environment Heat transfer, the latent energy of fusing are very big.The variation of pulverulence and the variation of corresponding hot attribute can all make hot biography The process of passing becomes complicated.
Step 5.1 is established using an apex angle of powder bed as origin O, is respectively X with two sides being connected with origin O Axis and Y-axis establish rectangular coordinate system O-XY;
Step 5.2 establishes temperature field finite element model in laser melting process using formula (5):
In formula (5), a is the thermal diffusivity of metal powder material, and T (t) is the transient temperature of t moment metal powder material,For Laplace operator;For the steady temperature field not changed over time, existT (x, y, z) be The temperature of metal powder material at point (x, y, z);
Step 5.3 obtains the temperature gradient in laser-irradiated domain along normal direction n using formula (6)
Enthalpy and boundary condition are changed according to physical condition, study the variation of temperature field of molten pool to laser fusing zero The influence of part uniformity and thermal stress.In this way, by the sound of Thermodynamics modeling and monitoring to laser melting process, temperature, Picture signal corroborates each other, and the reliability of laser melting process monitoring can be enhanced, and to realize that selectivity swashs from now on The feedback control of light fusion process and fusing compensation provide theoretical foundation.
The sparse coding of step 6, multi-source heterogeneous data:
The consistency that the research of sparse coding obtains multi-source heterogeneous monitoring information indicates, while realizing data compression, improves The pace of learning and accuracy of identification of depth network.Traditionally sampling thheorem, for high-frequency characteristic information common in monitoring, such as The higher harmonic wave components such as acoustic emission signal, ultrasonic signal need to obtain with several megahertzs of sample frequency, for the reality for monitoring system When property brings difficulty.In addition, the computationally intensive of the high dimensional datas such as temperature pattern processing, speed are slow, it is unfavorable for depth DBN model Training.
According to the compression sensing theory that Candes and Donoho was proposed in 2006, signal compression and sampling are merged into Row, by the study of redundant dictionary, obtains the rarefaction representation (measured value) of signal, the measurement data amount of such signal will be substantially less that Data volume required for traditional sampling method improves real-time processing speed.Since monitoring signals are nearly all not dilute in time domain Thin, thus this states the theoretical compression sampling for being not directly applicable monitoring signals.But we can pass through fast Fourier Transformation carries out rarefaction representation, then by one it is super it is suitable determine equation (redundant dictionary), one optimal norm problem of solution reconstructs Sparse signal.
Step 6.1 does not obtain the multi-source heterogeneous data that temperature, sound and picture signal are constituted by sensor components, It is denoted as f;
Step 6.2 obtains transformed multi-source heterogeneous data f to multi-source heterogeneous data f progress Fast Fourier Transform (FFT)T
Step 6.3, using redundant dictionary Φ to transformed multi-source heterogeneous data fTIt is reconstructed, obtains shown in formula (8) Transformed multi-source heterogeneous data fTRarefaction representation, and pass through optimal l shown in formula (7)0Norm constrains the sparse factor f′TNumber:
s.t.fT=Φ f 'T,fT∈Rk (8)
In formula (8), RkIndicate the real number field of k dimension;Φf′TIt indicates the signal atom set obtained after sparse coding, and has: Indicate the l-th signal atom obtained after sparse coding;L indicates that signal is former Sub- number;The sparse degree of signal is higher, and measurement data needed for recovering original signal using above formula also will be fewer.Multi-source is different The heat transfer agent of structure obtains the sparse expression of consistency after through redundant dictionary.In addition, the monitoring low for signal-to-noise ratio Signal can use dictionary learning method based on rarefaction representation, consider the original for learning pure noise Yu the signal containing noise respectively Son, and noise is separated using the correlation of atom.
The information of the selective laser melting process of multi-sensor collection is complicated and diversified.The selective laser of part is molten The state for changing quality and fusion process has direct relationship, and the corresponding state change such as nodularization, hole and crackle can be lain in In temperature, sound and image information.Using artificial intelligence later development, establishing has associative memory, self-adaptive processing energy The depth confidence neural network (DBN) of power, so as to comprehensive, complete information be obtained, to the part of selective laser melting Quality carries out fast and accurately on-line condition monitoring.
Step 7, to the signal atom set obtained after sparse codingCarry out Fusion Features Obtain observation sequence V={ v1,v2,...,vi,...,vn, viFor the observation data of i-th of visual layers;I=1,2 ..., n;N table Show the number of plies of visual layers;
Step 8 is obtained monitoring model online E (V, H | θ) using formula (8), and is realized with monitoring model online E (V, H | θ) To the on-line monitoring of laser gain material manufacturing process:
In formula (8), θ={ wij,ai,bjIt is parameter about RBM neural network model, wherein wijIndicate i-th it is visible The connection weight of layer and j-th of hidden layer, aiIndicate the biasing of i-th of visible layer, bjIndicate the biasing of j-th of hidden layer, hjIt indicates J-th of hidden layer;H indicates the set of hidden layer, and m indicates the number of plies of hidden layer.

Claims (1)

1.一种基于多源异构数据的激光增材制造过程的在线监测方法,其特征是按如下步骤进行:1. an on-line monitoring method based on the laser additive manufacturing process of multi-source heterogeneous data, is characterized in that carrying out as follows: 步骤1、利用式(1)建立基于高斯分布的激光能量分布I(r):Step 1. Use formula (1) to establish the laser energy distribution I(r) based on Gaussian distribution: 式(1)中,r为激光光斑上的点到激光光斑中心的距离,ω为激光光斑的半径,Φ为激光光斑的中心能量密度;In formula (1), r is the distance from the point on the laser spot to the center of the laser spot, ω is the radius of the laser spot, and Φ is the center energy density of the laser spot; 步骤2、利用式(2)得到介质振动的速度u:Step 2. Use formula (2) to obtain the speed u of medium vibration: 式(2)中,α为金属粉末材料对激光的吸收率;γ为气体的绝热指数,ρ0为金属粉末材料的密度;In formula (2), α is the absorptivity of the metal powder material to the laser light; γ is the adiabatic index of the gas, and ρ 0 is the density of the metal powder material; 步骤3、利用式(3)得到粉末床的最大表面温度TmStep 3. Use formula (3) to obtain the maximum surface temperature T m of the powder bed: 式(3)中,K为玻尔兹曼常数;k为金属粉末材料的导热系数;v为金属粉末材料的熔化速度;c为金属粉末材料的热熔比;In formula (3), K is the Boltzmann constant; k is the thermal conductivity of the metal powder material; v is the melting speed of the metal powder material; c is the heat-melting ratio of the metal powder material; 步骤4、利用式(4)得到熔池的宽度δwStep 4. Use formula (4) to obtain the width δ w of the molten pool: 式(4)中,ΔHlv为金属粉末材料从固态到气态的潜热能;Tlv为金属粉末材料从固态到气态的平衡温度;Tsl为金属粉末材料从固态到液态的平衡温度;In formula (4), ΔH lv is the latent heat energy of the metal powder material from solid to gas; T lv is the equilibrium temperature of the metal powder material from solid to gas; T sl is the equilibrium temperature of the metal powder material from solid to liquid; 步骤5、构建激光熔化过程中多场耦合的热力学模型:Step 5. Build a thermodynamic model of multi-field coupling in the laser melting process: 步骤5.1、建立以粉末床的一个顶角为原点O,以与所述原点O相连接的两条边分别为X轴和Y轴,建立直角坐标系O-XY;Step 5.1. Establish a Cartesian coordinate system O-XY with a vertex angle of the powder bed as the origin O, and the two sides connected with the origin O as the X axis and the Y axis respectively; 步骤5.2、利用式(5)建立激光熔化过程中的温度场有限元模型:Step 5.2. Use formula (5) to establish a finite element model of the temperature field in the laser melting process: 式(5)中,a为金属粉末材料的热扩散率,T(t)为t时刻金属粉末材料的瞬时温度,为拉普拉斯算子;对于不随时间变化的稳定温度场,存在T(x,y,z)为在点(x,y,z)处金属粉末材料的温度;In formula (5), a is the thermal diffusivity of the metal powder material, T(t) is the instantaneous temperature of the metal powder material at time t, is the Laplace operator; for a stable temperature field that does not vary with time, there is T(x,y,z) is the temperature of the metal powder material at point (x,y,z); 步骤5.3、利用式(6)得到在激光照射区域沿法线方向n的温度梯度 Step 5.3, use formula (6) to obtain the temperature gradient along the normal direction n in the laser irradiation area 步骤6、多源异构数据的稀疏编码:Step 6. Sparse coding of multi-source heterogeneous data: 步骤6.1、通过传感器组分别获得温度、声音和图像信号所构成的多源异构数据,记为f;Step 6.1. Obtain the multi-source heterogeneous data composed of temperature, sound and image signals through the sensor group, denoted as f; 步骤6.2、对所述多源异构数据f进行快速傅里叶变换得到变换后的多源异构数据fTStep 6.2, performing fast Fourier transform on the multi-source heterogeneous data f to obtain the multi-source heterogeneous data f T after the transformation; 步骤6.3、利用冗余字典Φ对所述变换后的多源异构数据fT进行重构,得到式(8)所示的变换后的多源异构数据fT的稀疏表示,并通过式(7)所示的最优l0范数来约束稀疏因子f′T的个数:Step 6.3. Use the redundant dictionary Φ to reconstruct the transformed multi-source heterogeneous data f T to obtain the sparse representation of the transformed multi-source heterogeneous data f T shown in formula (8), and use the formula The optimal l 0 norm shown in (7) is used to constrain the number of sparse factors f′ T : s.t.fT=Φf′T,fT∈Rk (8)stf T =Φf′ T ,f T ∈R k (8) 式(8)中,Rk表示k维的实数域;Φf′T表示稀疏编码后得到的信号原子集合,并有: 表示稀疏编码后得到的第L个信号原子;L表示信号原子个数;In formula (8), R k represents the k-dimensional real number field; Φf′ T represents the set of signal atoms obtained after sparse coding, and has: represents the Lth signal atom obtained after sparse coding; L represents the number of signal atoms; 步骤7、对稀疏编码后得到的信号原子集合进行特征融合得到观测序列V={v1,v2,...,vi,...,vn},vi为第i个可视层的观测数据;i=1,2,…,n;n表示可视层的层数;Step 7. The set of signal atoms obtained after sparse coding Perform feature fusion to obtain the observation sequence V={v 1 , v 2 ,...,v i ,...,v n }, where v i is the observation data of the ith visual layer; i=1,2,... ,n; n represents the number of layers of the visible layer; 步骤8、利用式(8)得到在线监测模型E(V,H|θ),并以所述在线监测模型E(V,H|θ)实现对激光增材制造过程的在线监测:Step 8. Obtain the online monitoring model E(V, H|θ) by using the formula (8), and realize the online monitoring of the laser additive manufacturing process with the online monitoring model E(V, H|θ): 式(8)中,θ={wij,ai,bj}是关于RBM神经网络模型的参数,其中,wij表示第i个可见层与第j个隐层的连接权值,ai表示第i个可见层的偏置,bj表示第j个隐藏层的偏置,hj表示第j个隐藏层;H表示隐藏层的集合,m表示隐藏层的层数。In formula (8), θ={w ij , a i , b j } is the parameter about the RBM neural network model, where w ij represents the connection weight between the ith visible layer and the j th hidden layer, a i represents the bias of the i-th visible layer, b j represents the bias of the j-th hidden layer, h j represents the j-th hidden layer; H represents the set of hidden layers, and m represents the number of hidden layers.
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