CN110414103A - A kind of metal parts increasing material manufacturing process temperature field predictor method - Google Patents
A kind of metal parts increasing material manufacturing process temperature field predictor method Download PDFInfo
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Abstract
The invention discloses a kind of methods for estimating metal parts increasing material manufacturing process temperature field, are based on numerical simulation and finite-difference algorithm, establish metal parts increasing material manufacturing dynamic temperature field.Including step 1, initializes increasing material manufacturing system mode, determines powder bed volume and side length of element, part material attribute；Step 2, three-dimensional part model and partitioning model and iteration time step-length are determined；Step 3, the ti moment is classified as by powdering state or scanning mode according to print state；Step 4, ti moment corresponding boundary condition is determined；Step 5, ti moment temperature field is calculated；Step 6, judge whether the ti moment is to print the last one moment；If then calculating terminates, 3 are otherwise entered step, is recycled with this, calculated until completing all moment.The invention temperature field predictor method computational efficiency is high, can fully consider each state boundaries condition in increasing material manufacturing, establish metal increasing material manufacturing dynamic temperature field, provides guarantee for structural design of fittings optimization and defect analysis.
Description
Technical field
The present invention relates to a kind of temperature field Prediction System technologies, and in particular to be that one kind estimates metal parts increasing material manufacturing
Process dynamics change of temperature field simultaneously provides the method and system of guarantee for metal parts structural design optimization and defect analysis, belongs to
Numerical simulation technology field.
Background technique
Metal increases material manufacturing technology is the new material moulding process based on discrete dynamics models thought.The technique approximation near net at
Type can produce required metal parts without mold apperance.With simple production process, production procedure is short, recovery rate of iron
The advantages that high, for structure is complicated, the metal parts of single and mini-batch production has unique advantage.The final precision of the part of production,
Surface quality, performance and metal increasing material manufacturing technique include that the parameters such as heat source temperature, Moving Heat Sources speed and material properties have then
Inseparable relationship.And the monitoring detection and the improvement of analogue simulation part quality in temperature field are excellent during metal increasing material manufacturing
Change important in inhibiting.
The monitoring detection means in temperature field is essentially sensed using infrared temperature during the existing increasing material manufacturing to metal
Device be detected and used thermocouple to powder bed surface temperature and is located at progress temperature measurement under powder bed substrate.These detection means are all
Temperature monitoring can only be carried out to the surface of powder bed, and be unable to measure the temperature changing process inside it.Increase material to disclose metal
The change procedure of powder bed bulk temperature field in manufacturing process, temperature field simulation are an effective means.
Temperature field simulation is one of the important application in numerical simulation field.Wherein the method for temperature field simulation includes: to have again
Limit volumetric method (FVM), finite difference calculus (FDM), FInite Element (FEM) etc..
FInite Element is based on variation principle and Weighted Residual algorithm.Its basic ideas are as follows: integrated according to Variational Principle
Equation；Mesh generation is carried out to model according to the shape of solving model；Determine the list for meeting interstitial content and solving precision requirement
First basic function；Unit basic function is approached, unit area is integrated, obtaining unit finite element equation；To unit finite element
Equation is cumulative to obtain overall finite element equation；BORDER PROCESSING；Solving finite element equation.
Finite difference calculus is one of the method that numerical simulation field uses earliest, and fundamental basis is using Taylor series expansion
Method construct difference, main difference form includes: forward difference, backward difference and centered difference again.Its basic solution throughway
Are as follows: the model partition solved is become into unit grids, is replaced with limited grid node and is continuously solved model.
Finite element method precision is optional, but required memory and calculation amount are huge when calculating, and parallel computation is not easy to realize.And have
Limit volumetric method is more suitable for fluid calculation, and parallel computation is easier to realize, but precision highest can only substantially realize second order.
Summary of the invention
The problem of for background technique, the present invention provide a kind of metal parts increasing material manufacturing process temperature field and estimate
Method, computational efficiency height can fully consider the boundary condition of each state in increasing material manufacturing with parallel computation, establish gold
Belong to part increasing material manufacturing dynamic temperature field, provides guarantee for metal parts structural design optimization and defect analysis.
In order to achieve the above technical purposes, the present invention is achieved through the following technical solutions:
A kind of metal parts increasing material manufacturing process temperature field predictor method is based on numerical simulation and finite-difference algorithm, builds
Vertical metal parts increasing material manufacturing dynamic temperature field, specifically includes the following steps:
Step 1, increasing material manufacturing system mode is initialized, powder bed volume and side length of element is determined, determines metal parts material
Attribute；
Step 2, it determines metal parts threedimensional model and according to side length of element partitioning model, determines iteration time step-length；
Three-dimensional matrice is converted by metal parts threedimensional model according to the side length of element that step 1 defines；
The metal parts material properties and side length of element defined according to step 1 determine iteration time step-length, and specific calculate changes
Steady state time step-length equation need to be met for time step, complete the parameter preparation stage of simulation；
Step 3, after starting simulation, the ti moment is classified as by powdering state or scanning mode according to print state；
Step 4, determine that ti moment corresponding boundary condition comes and then determines the heat transfer type on boundary；
Step 5, ti moment temperature field is calculated；
Ti moment temperature field is calculated using finite difference calculus and enthalpy method；
Step 6, judge whether the ti moment is otherwise to enter if then Temperature calculating terminates at the last one moment of printing
Step 3, it is recycled with this, until completing all moment Temperature calculatings, and is post-processed.
Increasing material manufacturing system mode includes: molten bath initial temperature, molten bath volume, dusty material initial temperature, light beam or electricity
Beamlet scanning speed, light beam or electron beam effective interaction depth and power, wherein dusty material is if any the pre-heat treatment, then powder
Material initial temperature is temperature after preheating；
Side length of element is defined according to simulation precision and powder bed length, simulation precision is higher, and side length of element is smaller, accordingly
Simulation time-consuming it is also longer, corresponding relationship is shown below:
In formula (1): L, W, H are respectively the length of powder bed；
tsimIt is time-consuming for simulation；
N indicates that computer can calculate the temperature field of several grids simultaneously；
The side length of a expression grid；
titerIndicate required time when computer calculates a grid temperature field；
The number of l expression iteration.
In step 2, taking iteration time step-length is the 1/2 of maximum steady state time step.
In step 3, powdering process be powder supply mechanism by roller either powder rake by metal parts powder material it is evenly laid out
On powder bed, for next layer of printing；
Print procedure is that laser beam or electron beam are melted according to the track irradiation powder material being sliced by part model
And printing, every layer of printing duration perceived model is depending on the sectional area of this layer and hot spot moving distance；Unit grids side length is not more than
Laser beam spot diameter, electron beam spot diameter and pool depth；
Two states are classified to be determined by the step number of current iteration, specifically includes the following steps:
Step 1, be multiplied according to iteration time step number with iteration time step-length available iteration duration, and printing time-consuming is under
Formula definition:
tTK=tp+t1+tp+t2+…+tp+tk (2)
In formula (2): tpIt is time-consuming for single layer powdering；
tkIt is scanned for kth layer time-consuming；
tTKTo print to k layers of total time-consuming；
Step 2, work as tiMoment is in tTKTo tTK+tpBetween when, tiMoment is powdering state；Work as tiMoment is in tTK-tkTo tTK
Between when, tiMoment is powdering state.
In step 4, the heat transfer type on boundary includes conduction and radiation, and coboundary and other horizontal boundary radiating modes are spoke
Heat dissipation, the boundary control equations of calculation basis heat loss through radiation are penetrated, lower boundary is heat loss through conduction, the boundary of calculation basis heat transfer heat dissipation
Governing equation；
Heat source includes laser beam, the radiant heating of electron beam and latent heat in print state
In the step 5: heat transfer governing equation and enthalpy method are unfolded to obtain its difference form according to finite difference calculus to be used for
Calculate temperature field.
In the step 6, when calculating temperature field, each iterative process result is saved or after several iterative process
It saves once, this skips number view iteration duration and simulation precision determines, specifically: when iteration duration is less than or equal to 0.1s,
Number is skipped about between 1000~10000；When iteration duration is greater than 0.1s, each iterative process result can be saved；
After completing Temperature calculating, reads each iterative process and strike a bargain as a result, result is drawn using the library plotly
Mutual formula image, to check the three-dimensional temperature field state of each process.
The beneficial effects of the present invention are:
The present invention is based on finite difference calculus, simulate entire increasing material manufacturing process by Temperature Field Simulation, obtain metal parts
Complete temperature field state and variation tendency in print procedure.Compared with existing FInite Element, finite difference calculus can be parallel
It calculates, therefore it is shorter to simulate time-consuming, while boundary condition treatment requirement is less, therefore emulates applicable model and limit less.By
In having used enthalpy method, the latent heat problem discharged when molten metal crystallization can be effectively calculated, therefore overall procedure is for optimization
Design of part, optimization print parameters and defect analysis such as analysis of Residual Stress etc. important in inhibiting.
Detailed description of the invention
Fig. 1 is flow diagram of the invention.
Fig. 2 is example powder bed and design of part schematic diagram of the invention.
Fig. 3 is grid dividing schematic diagram of the invention.
Fig. 4 is grid dividing normalized schematic diagram of the invention.
Fig. 5 is powder bed heat conduction path schematic diagram of the invention.
In figure, 1. grids；2. molten bath；3. being greater than 1/2 model part by volume after grid dividing；4. after grid dividing
Model part of the volume less than 1/2；5. powder bed；6. substrate.
Specific embodiment
The specific embodiment of this explanation is further described in detail with reference to the accompanying drawing:
The present invention proposes a kind of method and system for estimating metal parts increasing material manufacturing process temperature field, is based on numerical simulation
And finite difference calculus, it can fully consider the boundary condition of each state in increasing material manufacturing, it is dynamic to establish metal parts increasing material manufacturing
State temperature field provides guarantee for metal parts structural design optimization and defect analysis, and main flow is as shown in Figure 1.
The present invention is realized by following steps:
Step 1, increasing material manufacturing system mode is initialized, powder bed volume and side length of element is determined, determines metal parts material
Attribute；
Increasing material manufacturing system initial state include: molten bath initial temperature, molten bath size depth, dusty material initial temperature,
Light beam or beam scan velocity.Wherein dusty material is if any the pre-heat treatment, then dusty material initial temperature is temperature after preheating.
Side length of element is defined according to simulation precision and powder bed volume, simulation precision is higher, and side length of element is smaller, corresponding mould
Quasi- time-consuming is also longer.And unit grids side length should be not more than laser beam spot size or electron beam spot size, unit grids are deep
Degree is not more than pool depth, otherwise can not effectively be simulated to practical fusion process, as shown in Figure 2.
Grid used in simulating is usually square, can also be the mutually contour cuboid not waited of length and width, for square
Grid, side length of element take that the grid obtained after above-mentioned constraint is long, grid is wide and the minimum value of the high i.e. depth of grid.
Metal parts material properties need to include: thermal coefficient w/ (mK), density kg/m3, specific heat capacity J/ (kg DEG C), knot
Brilliant latent heat J/kg, solidus temperature DEG C, liquidus temperature DEG C.
Step 2, metal parts threedimensional model is determined and according to side length of element partitioning model, according to metal parts material properties
Iteration time step-length is determined with side length of element；
Three-dimensional matrice is converted by metal parts threedimensional model according to the side length of element that step 1 defines, by setting model
In three-dimensional meshed array, model is chosen using unit grids frame one by one, after frame choosing, completely by model in unit grids
Full of the case where, be set to 1 in computer array；In unit grids the case where complete model-free, it is set in computer array
0.For model after grid dividing not by unit grids be filled up completely or completely unfilled situation, calculate the model of the part
Product, if volume is greater than 1/2 unit grids volume, as shown in figure 4, being greater than 1/2 model part 3 by volume after grid dividing, then
The Partial Mesh is regarded to be filled up completely, 1 is set in computer array, is otherwise considered as and is not filled by completely, as shown in figure 4, by net
Irregular model part 4 after lattice division, volume are set to 0 in computer array less than 1/2 unit grids volume.
The metal parts material properties and side length of element defined according to step 1 determine iteration time step-length, when calculating iteration
Between step-length need to meet steady state time step-length equation, it is as follows:
In formula: ρ, Cp, λ be respectively metal parts material density, specific heat capacity, thermal coefficient；Δx2For the flat of side length of element
Side；
Constant 6 is three-dimensional grid parameter, for two-dimensional grid, constant value 4, one-dimensional grid, constant value 2.Usually take
Iteration time step-length is its maximum steady state time step 1/2, is shown below:
Step 3, according to print state by tiMoment is classified as powdering state or scanning mode；Metal increasing material manufacturing process packet
Powdering process and scanning process are included, two processes are alternately.Powdering process is that powder supply mechanism will by roller either powder rake
Metal parts powder material is evenly laid out on powder bed, for next layer of printing.Powdering duration is usually constant；Print procedure is laser beam
Or electron beam is melted and is printed according to the track irradiation powder material being sliced by part model.Every layer of printing duration perceived model
Depending on the sectional area of this layer and hot spot moving distance, value is not usually definite value.
Two states classification can be determined by the step number of current iteration.It is multiplied according to iteration time cloth number with iteration time step-length
Available iteration duration.Printing time-consuming can be defined by the formula:
tTK=tp+t1+tp+t2+…+tp+tk
In formula: tpTime-consuming, the t for single layer powderingkTime-consuming, t is scanned for kth layerTKTo print to k layers of total time-consuming.Work as tiMoment exists
tTKTo tTK+tpBetween when, tiMoment is powdering state；Work as tiMoment is in tTK-tkTo tTKBetween when, tiMoment is powdering state.
Each moment print state can be released by above formula.
Step 4, t is determinediMoment corresponding boundary condition；
As shown in figure 5, heat transfer type predominantly conducts and radiation since the powder bed where printing is vacuum.
Coboundary and other horizontal boundary radiating modes are heat loss through radiation, and powder bed 5 is not heat loss through radiation with 6 contact portion of substrate, below
Boundary, that is, Fig. 5 powder bed 5 and 6 contact portion of substrate are heat loss through conduction.
Heat loss through radiation boundary control equations are defined by the formula:
In formula: ε is heat-delivery surface radiance W/m2DEG C, σ is Stefan-Boltzmann constant, TKIt is absolute for current grid
Temperature K.
Heat loss through conduction boundary control equations are defined by the formula:
In formula: λ is the thermal coefficient of metal parts material；H is the coefficient of heat transfer；T∞For the temperature of extraneous medium infinity；
TsFor boundary grid temperature；
Heat source includes the radiant heating and latent heat of laser beam or electron beam in print state.
Step 5, t is calculated using finite difference calculus and enthalpy methodiMoment temperature field；
Heat transfer governing equation is defined by the formula:
In formula: T is current grid temperature；For differential of vector operator.
Above formula is expanded into three-dimensional differential form according to finite difference calculus, is shown below:
Wherein: αp(i, j, k)=1- αe(i,j,k)-αw(i,j,k)-αn(i,j,k)-αs(i,j,k)-αt(i,j,k)-αb
(i,j,k)；
In formula: T is current grid temperature；V is unit mesh volume；T is current time；
Enthalpy method processing latent heat three-dimensional differential equation is defined by the formula:
In formula: H is enthalpy.
Enthalpy is defined as follows shown in formula:
H=CpT+flLh
In formula: LhFor metal material latent heat；flFor the amount percentage of liquid phase substance in the unit grids.flValue is under
Formula determines:
In formula: fsFor the amount percentage of solid matter in the unit grids；TmFor solidus temperature；TlFor liquidus temperature.
The new temperature of grid is released by its corresponding enthalpy, is shown below:
In formula: HnewFor the new enthalpy of the unit grids；HsCorresponding enthalpy when being all solid phase for the unit grids；HlFor this
Unit grids are all enthalpy corresponding when liquid phase；
This external demand is to flIt is normalized, is allowed to be not less than 0 no more than 1；
For being greater than 1 flValue, enabling it is 1；
For the f less than 0lValue, enabling it is 0；
For the f in 0 to 1 sectionlValue, is not handled it.
Step 6, judge tiWhether the moment is to print the last one moment；If then Temperature calculating terminates, otherwise enter
Step 6, it is recycled with this, until completing all moment Temperature calculatings, and is post-processed.
When calculating temperature field, save each iterative process as a result, can also be saved after several iterative process it is primary,
This skips number view iteration duration and simulation precision determines；When iteration duration is less than or equal to 0.1s, number is skipped about 1000
Between~10000；When iteration duration is greater than 0.1s, each iterative process result can be saved.
After completing Temperature calculating, each iterative process result is read.Result is drawn using the library plotly and is struck a bargain
Mutual formula image, to check the three-dimensional temperature field state of each process.
Embodiment
Only it is with the metal increasing material manufacturing Ti-6AL-4V material cuboid component for choosing smelting technology based on electron beam below
It represents, illustrates the present invention is how to carry out simulation predicting to the temperature field of increasing material manufacturing process.
Firstly, model is long 15mm, wide 8mm, the rectangular tab of high 2mm, powder bed length and width is respectively 20mm and 20mm, such as
Shown in Fig. 2.The solidus temperature for printing powder material Ti-6AL-4V used is 1593 DEG C to 1615 DEG C, and liquidus temperature is 1635 DEG C
To 1674 DEG C, with this solidus temperature of drawing materials for 1593 DEG C, material liquid phase line temperature is 1635 DEG C, is preheated to powder material,
Preheating temperature is 360 DEG C, layer thickness 0.1mm, and molten bath initial temperature is 1700 DEG C, and it is 0.1mm that molten bath, which is similar to side length,
Square.Beam scan velocity is 50mm/s, and spot size is approximately the square of side length 0.05mm.Therefore setting grid
Side length is 0.05mm, and as shown in Fig. 3 grid 1,2 be molten bath.It is time-consuming that simulation can be estimated are as follows:
The density of material Ti-6AL-4V is about 4.5g/mm3, thermal coefficient is 15.24W/ (mK), specific heat capacity 612J/
Kg* DEG C, latent heat 9.73*108Jm-3。
After grid dividing, needs according to the single layer powdering time to be 10s, single layer can be released according to electron beam movement speed
Print time is about are as follows:
Iteration time step-length can be calculated simultaneously:
The above parameter is substituted into effective calculus of finite differences and enthalpy method, the temperature field at each moment can be acquired.
When calculating temperature field, save each iterative process as a result, can also be saved after several iterative process it is primary,
This skips number view iteration duration and simulation precision determines.In this example since iteration time step-length is shorter, selection is every
It is saved after 1000 iterative process primary.
After completing Temperature calculating, each iterative process result is read.This example is write using Python, easily
In realization parallel computation.And result is depicted as interactive image using the library plotly, to check the three-dimensional temperature of each process
Spend field state.
Claims (7)
1. a kind of metal parts increasing material manufacturing process temperature field predictor method, it is characterised in that: be based on numerical simulation and finite difference
Divide algorithm, establishes metal parts increasing material manufacturing dynamic temperature field, specifically includes the following steps:
Step 1, increasing material manufacturing system mode is initialized, powder bed volume and side length of element is determined, determines metal parts material properties；
Step 2, it determines metal parts threedimensional model and according to side length of element partitioning model, determines iteration time step-length；
Three-dimensional matrice is converted by metal parts threedimensional model according to the side length of element that step 1 defines；
The metal parts material properties and side length of element defined according to step 1 determine iteration time step-length, when specifically calculating iteration
Between step-length need to meet steady state time step-length equation, complete simulation the parameter preparation stage；
Step 3, after starting simulation, the ti moment is classified as by powdering state or scanning mode according to print state；
Step 4, determine that ti moment corresponding boundary condition comes and then determines the heat transfer type on boundary；
Step 5, ti moment temperature field is calculated；
Ti moment temperature field is calculated using finite difference calculus and enthalpy method；
Step 6, judge whether the ti moment is otherwise to enter step if then Temperature calculating terminates at the last one moment of printing
3, it is recycled with this, until completing all moment Temperature calculatings, and is post-processed.
2. metal parts increasing material manufacturing process temperature field according to claim 1 predictor method, it is characterised in that:
Increasing material manufacturing system mode includes: molten bath initial temperature, molten bath volume, dusty material initial temperature, light beam or electron beam
Scanning speed, light beam or electron beam effective interaction depth and power, wherein dusty material is if any the pre-heat treatment, then dusty material
Initial temperature is temperature after preheating；
Side length of element is defined according to simulation precision and powder bed volume, simulation precision is higher, and side length of element is smaller, corresponding simulation consumption
When it is also longer, corresponding relationship is shown below:
In formula (1): L, W, H are respectively the length of powder bed；
tsimIt is time-consuming for simulation；
N indicates that computer can calculate the temperature field of several grids simultaneously；
The side length of a expression grid；
titerIndicate required time when computer calculates a grid temperature field；
The number of l expression iteration.
3. metal parts increasing material manufacturing process temperature field according to claim 1 predictor method, it is characterised in that: step 2
In, taking iteration time step-length is the 1/2 of maximum steady state time step.
4. metal parts increasing material manufacturing process temperature field according to claim 1 predictor method, it is characterised in that: step 3
In, powdering process is that powder supply mechanism is evenly laid out on powder bed by metal parts powder material by roller either powder rake, is used for down
One layer of printing；
Print procedure is that laser beam or electron beam are melted and beaten according to the track irradiation powder material being sliced by part model
Print, every layer of printing duration perceived model is depending on the sectional area of this layer and hot spot moving distance；Unit grids side length is not more than laser
Beam spot diameter, electron beam spot diameter and pool depth；
Two states are classified to be determined by the step number of current iteration, specifically includes the following steps:
Step 3.1, be multiplied according to iteration time step number with iteration time step-length available iteration duration, and printing time-consuming is by following formula
Definition:
tTK=tp+t1+tp+t2+…+tp+tk (2)
In formula (2): tpIt is time-consuming for single layer powdering；
tkIt is scanned for kth layer time-consuming；
tTKTo print to k layers of total time-consuming；
Step 3.2, work as tiMoment is in tKTo tK+tpBetween when, tiMoment is powdering state；Work as tiMoment is in tK-tkTo tKBetween
When, tiMoment is powdering state.
5. metal parts increasing material manufacturing process temperature field according to claim 1 predictor method, it is characterised in that: step 4
In, the heat transfer type on boundary includes conduction and radiation, and coboundary and other horizontal boundary radiating modes are heat loss through radiation, calculate according to
According to the boundary control equations of heat loss through radiation, lower boundary is heat loss through conduction, the boundary control equations of calculation basis heat transfer heat dissipation；
Heat source includes laser beam, the radiant heating of electron beam and latent heat in print state.
6. metal parts increasing material manufacturing process temperature field according to claim 1 predictor method, it is characterised in that: the step
In rapid 5: heat transfer governing equation and enthalpy method foundation finite difference calculus are unfolded to obtain its difference form for calculating temperature field.
7. metal parts increasing material manufacturing process temperature field according to claim 1 predictor method, it is characterised in that: the step
In rapid 6, when calculating temperature field, saves each iterative process result or save primary, this jump after several iterative process
It crosses number view iteration duration and simulation precision determines, specifically: when iteration duration is less than or equal to 0.1s, skipping number and about exist
Between 1000~10000；When iteration duration is greater than 0.1s, each iterative process result can be saved；
After completing Temperature calculating, each iterative process is read as a result, result is depicted as interactive mode using the library plotly
Image, to check the three-dimensional temperature field state of each process.
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| CN111581820B (en) * | 2020-05-08 | 2022-10-21 | 中国工程物理研究院机械制造工艺研究所 | Novel simulation method for melting additive manufacturing process of laser area array selected area |
| CN112182908A (en) * | 2020-10-19 | 2021-01-05 | 北京适创科技有限公司 | Temperature solver establishing method for casting mold thermal balance analysis |
| CN112182908B (en) * | 2020-10-19 | 2024-04-02 | 北京适创科技有限公司 | Method for establishing temperature solver for casting mold thermal balance analysis |
| CN112988839A (en) * | 2021-03-16 | 2021-06-18 | 广东技术师范大学 | Aluminum profile electrostatic spraying unit powder consumption analysis method |
| CN116755644A (en) * | 2023-05-04 | 2023-09-15 | 上海杭和智能科技有限公司 | Prediction method of thermal history of wire arc additive manufacturing |
| CN116755644B (en) * | 2023-05-04 | 2024-07-05 | 上海杭和智能科技有限公司 | Prediction method of thermal history of wire arc additive manufacturing |
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