CN111090937B - Euler grid-based simulation processing method for scale of additive manufacturing process component - Google Patents
Euler grid-based simulation processing method for scale of additive manufacturing process component Download PDFInfo
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- CN111090937B CN111090937B CN201911289075.5A CN201911289075A CN111090937B CN 111090937 B CN111090937 B CN 111090937B CN 201911289075 A CN201911289075 A CN 201911289075A CN 111090937 B CN111090937 B CN 111090937B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
- B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F17/00—Digital computing or data processing equipment or methods, specially adapted for specific functions
- G06F17/10—Complex mathematical operations
- G06F17/11—Complex mathematical operations for solving equations, e.g. nonlinear equations, general mathematical optimization problems
Abstract
The invention provides a simulation processing method of the scale of a component of an additive manufacturing process based on Euler grids, belonging to the field of additive manufacturing modeling simulation. The simulation of the traditional component dimension has the problems of low precision or overlarge calculated amount and the like, and in order to realize high-fidelity and high-efficiency modeling of a solid heat transfer process, the Euler grid is adopted to discretize a calculation domain, a fine grid is adopted in a thin layer at the top of the calculation domain, and a coarse grid is used in other regions. When the height of a printing layer of the component is increased, the downward movement of the component in the vertical direction is realized by constructing a specific convection transport equation, and the laser spots are always positioned in a region with fine grid division at the top of the domain. On the premise of ensuring that the laser heat source has enough grid resolution, the whole grid quantity is reduced, and the grid does not need dynamic reconstruction. When the heat transfer modeling is carried out, a parameter for representing the printing state is introduced, so that the simulation processing method can automatically and sequentially process the printing of the component layer by the laser and the downward movement of the component after the printing of a certain layer is finished.
Description
Technical Field
The invention relates to the field of additive manufacturing modeling simulation, in particular to a simulation processing method of scale of a component of an additive manufacturing process based on Euler grids.
Background
Additive manufacturing is also known as 3D printing. In contrast to conventional manufacturing models, additive manufacturing is a rapid shaping of components by a layer-by-layer build-up of materials "from bottom to top", which makes possible the manufacture of components with complex structures. The most widely used technology in the current 3D printing and forming is to rapidly melt preset metal powder by adopting fine focusing light spots to directly obtain parts with arbitrary shapes and close to complete density.
Numerical simulation is an effective means for researching the additive manufacturing process mechanism. Especially, efficient simulation of heat transfer in the 3D printing process is the key for researching the forming quality of the component including deformation warping and residual stress. In the conventional simulation processing method, in order to accurately obtain the thermophysical field information in the calculation domain in the printing process, the calculation domain is subjected to very fine meshing, which directly results in that the calculation amount is extremely huge, so that the simulation of the component dimension becomes quite difficult. The simulation of solid heat transfer introduces large numerical calculation errors if the meshing of the calculation domains is rough. At present, it is feasible to use an adaptive grid capable of capturing the laser spot trajectory (laser spot working area) in real time to perform grid dynamic encryption. Although the adaptive grid reduces the whole grid quantity and improves the numerical calculation precision, the dynamic reconstruction algorithm of the grid increases larger additional calculation cost.
Disclosure of Invention
The technical purpose to be achieved by the embodiment of the invention is to provide a simulation processing method for the dimension of a member in an additive manufacturing process based on Euler grids, which is used for solving the problems that in the current typical laser additive manufacturing process, the dimension difference between a forming member and a laser heat source is huge, and the grid resolution problem exists in solid heat transfer simulation in the traditional forming process, so that the simulation precision is not high or the calculated amount is too large, and the like.
In order to solve the technical problem, an embodiment of the present invention provides a simulation processing method for a dimension of an additive manufacturing process component based on euler grids, including the following steps:
a, leading in a laser motion track of a target component;
discretizing the calculation domain by using Euler grids to obtain a fine grid area and a coarse grid area with fixed positions, wherein the grid density of the fine grid area is greater than that of the coarse grid area, and the fine grid area is a printing area of the laser spot;
c, establishing a control equation of a uniform heat transfer model;
d, executing printing simulation of the target component according to the laser motion track, wherein when the target component is positioned in a current printing layer in the fine grid area to be printed, solving a control equation according to a time layer advancing mode to obtain thermal physical field information on each grid node in the next time layer calculation domain;
e, judging whether the execution of the laser motion track is finished: if yes, ending the simulation, otherwise, entering a step F;
f, judging whether the current printing layer is printed completely: if the current printing layer is printed, controlling the target component to vertically move downwards for a preset distance, solving a control equation, updating thermal physical field information on each grid node in the calculation domain, enabling the next layer to be printed of the current printing layer to enter a fine grid region, and then returning to the step D to continue execution; and D, if the current printing layer is not printed, directly returning to the step D to continue executing.
Compared with the prior art, the simulation processing method of the dimension of the additive manufacturing process component based on the Euler grid has the following beneficial effects:
the invention provides a simulation processing method of the scale of a material increase manufacturing process component based on an Euler grid. A fine grid is used in the thin layer where the laser spot works at the top of the computational domain, while a coarse grid is used in other areas. With the increase of the layer height of the printing component, the component is gradually moved downwards in the vertical direction by constructing a specific convection transport equation, so that the laser spot is always positioned in a finely divided area of the grid at the top of the calculation domain. Therefore, the number of the whole grids is reduced, the grids do not need to be dynamically reconstructed, the calculation cost is reduced, and meanwhile, the sufficient grid resolution ratio for a laser heat source is ensured. During heat transfer modeling, a state parameter capable of judging the printing state is introduced, so that the simulation calculation method can automatically and orderly process the printing of the component layer by the laser and the downward movement work of the component after the printing of a certain layer is completed. In general, the simulation processing method provided by the invention realizes accurate and efficient simulation of the solid heat transfer process, not only ensures that a laser heat source and a path thereof have enough grid resolution, but also considers the simulation cost of high fidelity of component dimension.
Drawings
Fig. 1 is a schematic flow chart of a simulation processing method of the euler grid-based component scale of the additive manufacturing process according to the present invention;
FIG. 2 is a schematic diagram of a first half-process of printing a component using an additive manufacturing process based on an Euler grid according to the present invention;
FIG. 3 is a schematic diagram of an intermediate process for printing a component using an additive manufacturing process based on an Euler grid according to the present invention;
fig. 4 is a schematic diagram of a second half of the process of printing a component using an additive manufacturing process based on an euler grid according to the present invention.
Detailed Description
In order to make the technical problems, technical solutions and advantages of the present invention more apparent, the following detailed description is given with reference to the accompanying drawings and specific embodiments. In the following description, specific details such as specific configurations and components are provided only to help the full understanding of the embodiments of the present invention. Thus, it will be apparent to those skilled in the art that various changes and modifications may be made to the embodiments described herein without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
It should be appreciated that reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
In various embodiments of the present invention, it should be understood that the sequence numbers of the following processes do not mean the execution sequence, and the execution sequence of each process should be determined by its function and inherent logic, and should not constitute any limitation to the implementation process of the embodiments of the present invention.
It should be understood that the term "and/or" herein is merely one type of association relationship that describes an associated object, meaning that three relationships may exist, e.g., a and/or B may mean: a exists alone, A and B exist simultaneously, and B exists alone. In addition, the character "/" herein generally indicates that the former and latter related objects are in an "or" relationship.
In the embodiments provided herein, it should be understood that "B corresponding to a" means that B is associated with a from which B can be determined. It should also be understood that determining B from a does not mean determining B from a alone, but may be determined from a and/or other information.
Referring to fig. 1-4, a printing process for a teapot component 4 as a target component is simulated for an embodiment of the present invention. According to the flow chart in fig. 1, step S101 is first executed to introduce the laser movement track of the teapot component 4 to be printed. The laser trajectory divides the entire teapot component 4 into a plurality of printed layers depending on the height of the teapot component 4 and the thickness of the printed layers which are predetermined.
And step S102 is executed again, discretization processing is performed on the calculation domain where the teapot component 4 is located by using euler grids, and a fine grid region 1 and a coarse grid region 2 with fixed positions are obtained, which is specifically shown in fig. 2 to 4. Wherein, the fine grid area 1 is a printing area of the laser spot, and the grid density of the fine grid area 1 is greater than that of the coarse grid area 2. Therefore, when simulation is carried out, the grid resolution in the fine grid area 1 is enough to capture the finely focused laser light spots emitted by the laser heat source 3, the accuracy during printing is ensured, and the heat transfer process of the teapot component 4 during printing can be accurately simulated. Meanwhile, the other regions in the computation domain are coarse mesh regions 2 with a smaller mesh density. By reducing the overall number of grids and avoiding dynamic reconfiguration of the grids, not only is the overall amount of computation of the teapot components 4 during simulation reduced, but also the feasibility and high efficiency of high fidelity simulation of the teapot components 4 are ensured.
When the laser prints a certain layer of the teapot component 4 according to the introduced motion track, step S103 is executed to establish a control equation of a unified heat transfer model:
wherein rho is the density of a physical property parameter; c is the specific heat capacity of the physical property parameter; k is the coefficient of thermal conductivity of physical parameters; gamma-shapedLSIs the preset heat flux of the laser; sTIs a preset heat source item; t is a time variable; t is the temperature; u is the moving speed of the target member; α is a printing state control parameter. When the printed teapot component 4 is located in the current printed layer print in the fine-grid area, α is 0; when the printing of the current printing layer is finished and the teapot component 4 moves downwards, alpha is equal to 1. Wherein, by introducing the printing state control parameter α, different control equations can be obtained when the printing state control parameter α is equal to different values. Furthermore, when the teapot component 4 is in different printing states, corresponding thermal physical field information can be obtained, which is convenient for the follow-up process according to the thermal physical field informationStudies were conducted including distribution of deformation warpage and residual stress of the member.
And step S104 is executed, and printing simulation of the teapot component 4 is executed according to the laser motion track. Wherein when the printed target member is located in the current printing layer in the fine mesh region for printing, the printing state control parameter α is 0, and the control equation is the following solid heat transfer control equation:
solving the control equation according to a time layer advancing mode to obtain the thermal physical field information of each grid node in the next time layer calculation domain. When solving the control equation in a time-horizon advancing manner, the simulation time of each time horizon is updated according to the following time update formula (step S105), where the time update formula is:
tn+1＝tn+(1-α)Δt
wherein, tnAnd tn+1Respectively representing simulation time on the nth time layer and the (n + 1) th time layer; Δ t is the time step. The time updating formula comprises a printing state control parameter alpha, so that when a printed target component is positioned in a current printing layer in the fine grid area 1 for printing, time layers can be normally advanced, and each time layer can acquire thermal physical field information on each grid node in a corresponding calculation domain during printing; when the teapot component 4 moves down after the printing of the current printing layer is finished, the current printing layer can be kept unchanged, and the accuracy of the obtained thermal physical field information is ensured.
And after obtaining the thermophysical field information on each grid node in the current time-layer calculation domain, executing step S106, and judging whether the execution of the laser motion track is finished. And when the judgment result is that the laser track is completely executed, determining that the simulation process of the whole teapot component 4 is completed, executing step S107, outputting the thermal physical field information on each grid node obtained in the simulation process, and ending the simulation.
And when the judgment result is that the laser track is not executed completely, determining that the simulation needs to be continued, and executing step S108 to judge whether the current printing layer is printed completely. And when the current printing layer is not printed, returning to the step S104, and continuing to perform the printing simulation of the current printing layer.
When the printing of the currently printed layer is completed, the next layer to be printed of the teapot component 4 needs to be printed at this time. According to the invention, the teapot component 4 is controlled to move downwards, so that the next layer to be printed of the teapot component 4 enters the fine grid area 1, rather than controlling the laser spots to move to the next layer to be printed, and thus, the calculation amount of model simulation can be greatly reduced. Specifically, step S109 is executed to control the teapot component 4 to move vertically downward by a preset distance h, and a control equation is solved; when the teapot component 4 moves downwards after the printing of the current printing layer is finished, the printing state control parameter alpha is 1, and the control equation is the following convection transport equation:
wherein u is ux，uy，uz)＝(0，0，uz)，
By solving the control equation, the thermal physical field information on each grid node in the calculation domain can be updated, so that the current printing layer is moved down, and the next layer to be printed is also positioned in the fine grid region 1. Therefore, the teapot component 4 and the corresponding thermal physical field information can move synchronously, and the accuracy of the thermal physical field information is ensured. After the next layer to be printed enters the fine grid area 1, the printing layer is updated to be the current printing layer, so that the current printing layer which is being printed is always positioned in the fine grid area 1 with larger grid density in the laser printing process, and the calculation accuracy of the related physical quantity is ensured.
Specifically, the moving speed is u ═ ux，uy，uz)＝(0，0，uz). Wherein the moving speed in the vertical directionuzDetermined according to the following velocity formula:
therefore, the moving speed u can be obtained, and the downward movement of the teapot component 4 and the corresponding thermal physical field information is further ensured.
After the downward movement is completed and the next layer to be printed is updated to the current printing layer, the process returns to step S104, and the simulation is continued.
Note that the vertical direction herein is a direction perpendicular to the plane of the print layer. The downshifting is to move from the fine mesh region 1 to the coarse mesh region 2 in the vertical direction. The next layer to be printed is the first printing layer which is positioned behind the current printing layer in the laser motion track according to the printing sequence.
Preferably, the teapot member 4 is moved vertically downwards by a predetermined distance h equal to the thickness of one printed layer.
Furthermore, the present invention may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
It is further noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (5)
1. A simulation processing method of the dimension of an additive manufacturing process component based on Euler grids is characterized by comprising the following steps:
a, leading in a laser motion track of a target component;
discretizing the calculation domain by using an Euler grid to obtain a fine grid area and a coarse grid area with fixed positions, wherein the grid density of the fine grid area is greater than that of the coarse grid area, and the fine grid area is a printing area of the laser spot;
c, establishing a control equation of a uniform heat transfer model;
d, executing printing simulation of a target component according to the laser motion track, wherein when the target component is positioned in the current printing layer in the fine grid area to be printed, solving the control equation according to a time layer advancing mode to obtain thermal physical field information of each grid node in the calculation domain of the next time layer; wherein the formula t is updated according to time while solving the control equation in a time-horizon advancing mannern+1＝tn+ (1- α) Δ t to update the simulation time, t, at each temporal levelnAnd tn+1Respectively simulation time on the nth time layer and the (n + 1) th time layer, wherein delta t is a time step;
e, judging whether the execution of the laser motion track is finished: if yes, ending the simulation, otherwise, entering a step F;
f, judging whether the current printing layer is printed or not: if the current printing layer is printed, controlling the target component to vertically move downwards for a preset distance, solving the control equation, updating the thermal physical field information on each grid node in the calculation domain, enabling the next layer to be printed of the current printing layer to enter the fine grid area, and then returning to the step D to continue to execute; and D, if the current printing layer is not printed, directly returning to the step D to continue executing.
2. The simulation processing method according to claim 1,
the control equation is:
wherein rho is the density of a physical property parameter;
c is the specific heat capacity of the physical property parameter;
k is the coefficient of thermal conductivity of physical parameters;
ΓLSis the preset heat flux of the laser;
STis a preset heat source item;
t is a time variable;
t is the temperature;
u is the moving speed of the target member;
α is a printing state control parameter, and when a printing target member is located in the current printing layer in the fine mesh region to be printed, α is 0; when the target member moves down after the printing of the current printing layer is finished, alpha is 1.
3. The simulation processing method according to claim 2,
when the target member is located in the fine mesh area and the current printing layer is printed, solving the control equation as follows:
4. the simulation processing method according to claim 2,
when the printing of the current printing layer is finished, controlling the target component to vertically move downwards for a preset distance, solving the control equation, and updating the thermal physical field information on each grid node in the calculation domain; the target member moves downward at a speed u ═(ux，uy，uz)＝(0，0，uz) Wherein the moving speed u in the vertical directionzSolving according to the following velocity formula:
wherein h is a preset distance for the target member to move vertically downward.
5. The simulation processing method according to claim 4,
when the printing of the current printing layer is finished, solving a control equation as follows:
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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 |
| CN113561491B (en) * | 2021-07-25 | 2022-05-13 | 大连理工大学 | Biological 3D printing path planning method based on Euler loop |
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