CN113042752B - Method for identifying any fused shape and virtually printing by regional scanning of laser powder bed - Google Patents
Method for identifying any fused shape and virtually printing by regional scanning of laser powder bed Download PDFInfo
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Abstract
The invention provides a method for identifying any molten shape of a laser powder bed and virtually printing by regional scanning. Planning a path of each area according to the single-area or multi-area scanning requirement; in each area, determining the starting point and the end point of each scanning line, calculating the coordinates of the laser center at each moment in the laser movement process, and combining a thermal fluid model to realize the internal filling scanning and the profile scanning of the complex structure. According to the method, the scanning path can be generated only by inputting the geometric model and the rotation angle of the scanning path, a path algorithm is not required to be independently constructed for each scanning area, the efficiency is high, and simulation of the melting process of the laser powder bed under the condition of path planning with a complex geometric shape becomes possible; different path planning schemes can be customized by the internal filling path, and a more convenient method is provided for analyzing the advantages and the disadvantages of different scanning paths.
Description
Technical Field
The invention belongs to the technical field of laser additive manufacturing and rapid forming, and particularly relates to a method for identifying any molten shape of a laser powder bed and virtually printing by regional scanning.
Background
The laser powder bed melting forming is taken as a branch of the 3D printing technology, a mode of presetting the powder bed is adopted, high-power laser beams are utilized to directly melt all metal powder without adhesives, and the laser powder bed melting forming method has the advantages of being rapid in manufacturing, high in forming piece density, high in manufacturing precision, capable of forming parts in any complex shape and the like. Although this technique has many unique advantages and the forming process has begun to advance commercially with the rapid development of laser melting technology, there are still certain problems in the parts produced at the present stage, such as structural defects, e.g., cracks, voids, etc. Among other things, residual stresses and the resulting deformations tend to produce dimensional errors in the part, which defects seriously hinder the widespread use of this technique.
The simulation of the process of melting parts by the laser powder bed is an important method for deeply knowing the physical law and improving the quality of the parts. For virtual printing of structural members with different shapes, shape features need to be identified and scanning paths need to be planned. In general commercial software, a specific path planning program needs to be written for a specific shape, and if the scanning mode needs to be changed, the operation needs to be repeated again. The invention designs a general shape recognition and path planning framework, so that the path can be automatically generated by inputting specific input parameters for internal filling scanning and contour scanning of any shape. The method has important significance for improving the modeling efficiency and promoting the further development of the virtual printing of the laser powder bed fusion forming.
Disclosure of Invention
The invention aims to provide a virtual printing method for identifying any fused shape and scanning by regions by a laser powder bed aiming at the defects of the prior art.
The invention adopts the following technical scheme:
a virtual printing method for identifying any fused shape and scanning in different areas of a laser powder bed comprises the following steps:
s1, according to the shape of the geometric model, adopting a method of importing stl geometric files for a geometric body with a complex shape, adopting a method of reading coordinate information of each vertex for a quadrangle to identify the shape, and setting a rotation angle of a scanning line relative to an X axis;
s2, planning the scanning path of the inner part and the outline of each area according to the single-area or multi-area printing method;
s3, constructing a three-dimensional model control equation of the laser powder bed melting process;
s4, establishing a three-dimensional geometric model of the spatial powder bed, introducing the powder model into the thermal fluid model, constructing the thermal fluid model of the powder bed, setting initial and boundary conditions of a calculation domain, and performing grid division;
and S5, virtually printing the arbitrary geometric structures identified in the S1 in the thermal fluid model according to the planned paths.
Further, in S1, when the geometric model is a quadrangle, coordinate information of four vertices of the quadrangle is read, rotation angles of the scanning lines for scanning the respective regions with respect to the X axis are set, and angles of the contour lines of the respective regions with respect to the positive direction of the X axis are calculated.
Further, in S1, when the geometric model is a complex geometric body, an external stl model importing method is adopted; for an stl geometric body input externally, firstly, setting a model value for each grid, wherein the initial model values are all 0; when an stl geometric file is imported, setting the alpha value of a grid unit of the stl geometric file in the model as 1; traversing all grids of the computational domain, and when the alpha of a grid = 1, making the model of the grid = 1; after the traversal is completed, let the substrate region alpha = 1 under the stl document to distinguish the metal region and the gas region of the calculation model.
Further, when the geometric model is a quadrangle, the geometrical model is divided into single-area scanning and multi-area scanning; for single region scanning, a unit vector is obtained by four vertexes A, B, C and D
(ii) a For multi-region scanning, the quadrilateral ABCD is divided into several regions by line segments.
Further, for single-region scanning, specifically:
(1) by comparing the scan angles alpha1Selecting the coordinate of the starting point of the scanning path according to the angle of the straight line AB, and constructing the over-starting point with the angle alpha1The linear equation is a single scanning path filled inside, and the linear plane is translated to generate all paths filled inside the whole current quadrilateral area;
(2) translating a linear equation to an initial scanning position by the radius of the laser to start scanning, and obtaining a unit vector pointing to an end point from a start point and the end point of a single scanning path for each scanning path
Setting initial point coordinates as (px, py), current scanning track running time t and speed as v, and calculating to obtain x-axis coordinates and y-axis coordinates of the laser center at each moment;
(3) judging the relation between the x-axis coordinate and the y-axis coordinate of the current laser center and the current scanning area at each time step, if the current coordinate of the laser center does not exceed the quadrilateral area, indicating that the scanning is not finished, and calculating the laser coordinate of the next moment according to the scanning speed, the time and the vector value of the single path; if the current coordinate of the laser center exceeds the quadrilateral area, the scanning of the path is finished, a single-channel cooling stage is entered, and the initial point coordinate and the end point coordinate of the next scanning path are initialized; if the straight line of the next scanning path exceeds the quadrilateral area, the end of the internal filling scanning is indicated.
For multi-region scanning, specifically: with reference to the scanning method of a single area, according to the scanning angle alpha2And performing internal path planning and laser scanning of another part of area.
Furthermore, two intersection points of the linear equation and the contour equation are respectively an initial point and an end point of the scanning path; the contour equation is a linear equation of straight lines AB, BC, CD and DA which are obtained by calculation of four vertexes A, B, C and D; the contour scanning mode takes the point A as a starting point and sequentially follows the vector
Is moved. One coordinate value is fixed at a time, and another coordinate value is calculated by scanning speed, time and vector coordinates.
Further, according to the scanning interval m and the scanning angle alpha between the adjacent scanning tracks1The actual offset distance of the straight line along the Y-axis direction is calculated by:
further, the coordinate calculation formula of the laser center position is as follows:
further, the linear equation is shifted by a distance of m' along the positive direction of the Y axis, and the linear equation where the next scanning path is located is obtained:
furthermore, a partitioned printing algorithm is implanted into the thermal fluid model, and the algorithm realizes outline identification and path planning of the polygon, so that the interior of any quadrangle is filled, the outline is scanned, and virtual printing is realized.
Furthermore, for multi-area scanning, each area is scanned and filled in sequence, and if all the quadrilateral areas are filled completely, a cooling stage and an outline scanning stage are carried out.
The invention has the beneficial effects that:
1. the invention simplifies the quadrilateral scanning method, can generate the scanning path only by inputting the coordinates and the scanning angles of the four vertexes of the quadrilateral, saves the process of independently constructing a path algorithm for each quadrilateral, and has higher efficiency;
2. the method can identify the complex geometry body in an stl file import mode, so that the path planning of the complex geometry body becomes possible;
3. the invention can adopt different area division schemes of single area and multiple areas for the quadrilateral internal filling path, can customize different path planning schemes for each area, and provides a more convenient method for analyzing the advantages and disadvantages of different scanning paths.
Description of the drawings:
FIG. 1 illustrates the identification of stl geometry;
FIG. 2 is a graph of the scan path equation and the dotted distance for the left half of the area;
FIG. 3 is a diagram of the scan path equation and the dotted distance for the right half region;
FIG. 4 is a block scan, (b) a unidirectional scan, and (c) a serpentine scan of different path planning schemes;
FIG. 5 is a scanning example corresponding to a block scanning path;
FIG. 6 shows an example of a scan corresponding to a unidirectional scan path;
FIG. 7 is a scanning example corresponding to a serpentine scanning path;
fig. 8 is a path planning scheme for multiple zones: unidirectional scanning;
fig. 9 is a multi-region path planning scheme: and (4) bidirectional scanning.
The specific implementation mode is as follows:
in order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
The embodiment of the invention provides a method for identifying any molten shape of a laser powder bed and virtually printing by regional scanning, which comprises the following steps:
step one, setting a laser scanning area, and distinguishing according to the type of a laser scanning pattern: (1) planar quadrilateral, (2) external stl file geometry. Reading four tops of a quadrangle clockwise for a plane quadrangleCoordinate information of the points A, B, C, D, and reading the rotation angle alpha of the scanning direction relative to the X axis1And alpha2(scan angle); and aiming at the complex geometric model, external stl model introduction is adopted to plan a scanning path.
For a planar quadrilateral:
s1, planning the path of the thermal fluid model aiming at the single area, introducing the path by a plane quadrilateral area shown in figure 2, and obtaining a unit vector by four vertexes A, B, C and D
. Obtaining the angle alpha of the scanning line1。
Stl geometry for external input:
when the geometric model is a complex geometric model, an external stl model is adopted for importing; for an stl geometric body input externally, firstly, setting a model value for each grid, wherein the initial model values are all 0; when an stl geometric file is imported, setting the alpha value of a grid unit of the stl file in the model as 1; alpha = 1 indicates that the partial mesh region is a metal region. At this time, except for stl introduced, alpha = 0 of the remaining mesh is expressed as a gas domain. Traversing all grids of the computational domain, and when the alpha of a grid = 1, making the model of the grid = 1; after the traversal is completed, let the substrate region alpha = 1 under the stl document to distinguish the metal region and the gas region of the calculation model. The model after recognition is shown in fig. 1. The upper gray area in the figure is the identified stl geometric model.
Step two: and planning the scanning path of the interior and the outline of each area according to a single-area or multi-area printing method.
For a planar quadrilateral: divided into single-area scanning and multi-area scanning.
(1) Single-region scanning method:
s1, planning the thermal fluid model path for a single region, which is described with reference to the planar quadrilateral region shown in fig. 2, as shown in fig. 2, according to the coordinate information of the four vertices a, B, C, D of the quadrilateral being read in clockwise, the rotation angle (scanning angle) of the scanning direction relative to the X-axis being read, and the four rotation angles are calculatedAnd calculating the straight line equations of the straight lines AB, BC, CD and DA by the vertexes A, B, C and D. Selecting the coordinates of the starting point of the scanning path when the laser is filled inside, and constructing the over-starting point with the angle of alpha1The linear equation of the scanning line is
. The linear equation is a single scanning path of the internal filling, and the linear plane is translated to generate all paths of the internal filling of the whole current quadrilateral area.
From the scanning interval m between adjacent scanning tracks and the rotation angle alpha1The actual offset distance of the straight line along the Y-axis direction is calculated by the following formula
：
。
The laser scanning starting point is the intersection point p of the linear equation of the scanning line and the straight line DA, and the end point is the intersection point q of the linear equation of the scanning line and the straight line AB.
S2, obtaining a unit vector pointing from the start point to the end point from the start point and the end point of the single scanning path
Setting the initial point coordinates as (px, py), the running time of the current path at each moment as t, and the speed as v, and calculating the x-axis coordinate and the y-axis coordinate of the laser center at each moment according to the following formula.
S3, judging the relation between the x-axis coordinate and the y-axis coordinate of the current laser center and the current scanning area ABCD at each time stepFor each single-channel scanning in filling scanning, if the current coordinate of the laser scanning center does not exceed the quadrilateral area, the scanning of the current scanning channel is not finished, and the laser coordinate of the next moment is calculated according to the scanning speed, the scanning time and the vector value of the single-channel path; if the current coordinate of the laser scanning center exceeds the quadrilateral area, the scanning of the path is finished, a single cooling stage is entered, and the initial point coordinate and the end point coordinate of the next scanning path are initialized; at this time, the linear equation is shifted by a distance of m' along the positive direction of the Y axis, and the linear equation of the next scanning path is obtained:
。
if the scanning line intersects the outline ABCD of the quadrangle at two points, the scanning line is the initial scanning point and the end scanning point. If the straight line does not intersect with the outline ABCD of the quadrangle, the filling scanning is finished, and the outline scanning stage is entered.
The contour scanning mode takes the point A as a starting point and sequentially follows the vector
Is moved. Each time the coordinate values in x and y are fixed, another coordinate value is calculated by scanning speed, time and vector coordinates.
Furthermore, by interchanging the coordinates of the start and end points, different scanning patterns can be varied. As shown in fig. 4, there are 3 different paths presented here.
(2) The multi-area scanning method comprises the following steps:
the internal path planning of the single area can be further extended to the path planning of multiple areas. In this embodiment, a single area is divided into two areas, and a multi-area scanning method is described. Fig. 2 to 3 show a schematic diagram of a path planning method, in which a quadrilateral ABCD is divided into a left part and a right part by a line segment ef.
Firstly, selecting the initial point coordinates of the left half area AefD, and constructing a linear equation. The inside filling scan of the left half area is performed with reference to the scanning method of the single area.
If the scanning inside the left half-part area AefD is finished, the inside filling scanning of the right half-part area eBCf area is performed, and for the right half-part area, as shown in fig. 3, the coordinates of the starting point of the path are selected, the starting point is constructed, and the scanning direction is rotated by an angle α relative to the X axis2The equation of the line of the scan line is
。
From the scanning interval m between adjacent scanning tracks and the rotation angle alpha2The actual offset distance of the straight line along the Y-axis direction is calculated by the following formula
：
。
The laser scanning starting point is the intersection point p of the linear equation of the scanning line and the straight line ef, and the end point is the intersection point q of the linear equation of the scanning line and the straight line AB.
And performing internal filling scanning on the right half part by referring to the scanning method of the single region, and entering a cooling stage and a contour scanning stage if the quadrilateral region of the right half part is completely filled.
Step three, constructing a three-dimensional model control equation of the laser powder bed melting process;
establishing a mass conservation equation, a momentum conservation equation and an energy conservation equation:
conservation of mass equation:
the conservation of momentum equation:
energy conservation equation:
wherein
In order to be the density of the mixture,
in order to be the flow rate of the gas,
is the dynamic viscosity of the mixture of the oil and the water,
is the pressure of the gas to be heated,
in order to be the acceleration of the gravity,
，
，
，
the molten metal flow forces are respectively the marangoni force, the steam recoil pressure, the surface tension and the damping force.
Is the specific heat capacity, k is the thermal conductivity, T is the temperature,
and
respectively heat lossAnd laser energy input. And S is an upper source term of the energy equation. And (4) carrying out finite volume dispersion on the equation, and determining the size of each time step.
The heat source used for this model was a gaussian heat source:
wherein
In order to be a distribution factor, the distribution factor,
in order to be able to absorb the water,
laser power, r laser radius, (x0, y0) is the laser beam center coordinate.
Establishing a three-dimensional geometric model of the space powder bed, introducing the powder model into the hot fluid model, constructing the hot fluid model of the powder bed, setting initial and boundary conditions of a calculation domain, and performing grid division.
The model adopts Ti-6Al-4V as a deposition material, and the thermophysical parameters of the material are shown in Table 1:
TABLE 1 Main thermophysical parameters of Ti6Al4V
And (4) performing melting solidification calculation on the thermal fluid model by adopting a regional scanning method. FIGS. 5-7 show examples of the scanning of the three paths of FIG. 4, in which the white dotted line is a quadrilateral outline. In fig. 8 and 9, a solid structure is constructed by performing single-layer and multi-layer virtual printing at each time based on the geometric model profile, the laser center coordinates, and the scanning speed input in S1. By interchanging the coordinates of the starting point and the end point or inputting different rotation angles alpha1And alpha2Different scanning modes are changed. FIG. 8 and FIG. 8The different scanning paths that can be applied in the fusion of 6 laser powder beds are shown in 9, wherein the white dotted line is a quadrilateral outline, and the black area is a substrate.
The invention provides a method for identifying any fused shape and virtually printing by regional scanning of a laser powder bed. Planning a path of each area according to the scanning requirement of a single area or multiple areas; in each area, determining a starting point and an end point of each scanning line according to the scanning distance, the rotation angle and the geometric profile, and calculating to obtain a coordinate value of the laser center at each moment according to the current time, the current speed and a unit vector pointing from the scanning starting point to the end point. And in combination with the heat fluid model, internal filling scanning and contour scanning of the complex structure can be realized. Compared with the prior forming technology, the scanning path can be generated only by inputting the coordinates and the angles of the four vertexes of the quadrangle. The process of independently constructing the path algorithm for each quadrilateral is omitted, and the efficiency is higher. For complex geometry, the complex geometry can be identified by means of stl file import, so that path planning of the complex geometry is possible. And for the inner filling path of the quadrangle, a region division scheme different from a single region and a plurality of regions can be adopted. For each region, a different path planning scheme may be customized. A more convenient method is provided for analyzing the advantages and the disadvantages of different scanning paths.
The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention, it should be noted that, for those skilled in the art, several modifications and decorations without departing from the principle of the present invention should be regarded as the protection scope of the present invention.
Claims (8)
1. A virtual printing method for identifying any fused shape and scanning in different areas of a laser powder bed is characterized by comprising the following steps:
s1, adopting a stl geometric file importing method for a geometric body with a complex shape according to the shape of the geometric model, adopting a method of reading coordinate information of each vertex for a quadrangle to identify the shape, and setting a rotation angle of a scanning line relative to an X axis;
s2, planning the scanning path of the inner part and the outline of each area according to the single-area or multi-area printing method;
s3, constructing a three-dimensional model control equation of the laser powder bed melting process;
s4, establishing a three-dimensional geometric model of the spatial powder bed, introducing the powder model into the thermal fluid model, constructing the thermal fluid model of the powder bed, setting initial and boundary conditions of a calculation domain, and performing grid division;
s5, virtually printing the any geometric structure identified in the S1 according to the planned path in the thermal fluid model;
when the geometric model is a quadrangle, the method comprises single-area scanning and multi-area scanning; for single region scanning, a unit vector is obtained by four vertexes A, B, C and D
(ii) a For multi-area scanning, dividing a quadrilateral ABCD into a plurality of areas through line segments;
for single-region scanning, specifically:
(1) selecting the coordinates of the starting point of the scanning path, and constructing the over-starting point with the angle alpha1The linear equation is a single scanning path filled inside, and the linear plane is translated to generate all paths filled inside the whole current quadrilateral area;
(2) translating a linear equation to an initial scanning position by the radius of the laser to start scanning, and obtaining a unit vector pointing to an end point from a start point by using the start point and the end point of a single scanning path for each scanning path
Setting the initial point coordinate as (px, py), the current scanning track running time t and the speed as v, and calculating to obtainX and y axis coordinates of the laser center at each moment;
(3) judging the relation between the x-axis coordinate and the y-axis coordinate of the current laser center and the current scanning area at each time step, if the current coordinate of the laser center does not exceed the quadrilateral area, indicating that the scanning is not finished, and calculating the laser coordinate of the next moment according to the scanning speed, the time and the vector value of the single path; if the current coordinate of the laser center exceeds the quadrilateral area, the scanning of the path is finished, a single cooling stage is entered, and the initial point coordinate and the end point coordinate of the next scanning path are initialized; if the straight line of the next scanning path exceeds the quadrilateral area, the internal filling scanning is finished;
for multi-region scanning, in particular:
with reference to the scanning method of a single area, according to the scanning angle alpha2And performing internal path planning and laser scanning of other areas.
2. The method for virtual printing of arbitrary shape recognition and divisional scanning for laser powder bed melting according to claim 1, wherein in S1, when the geometric model is a quadrangle, coordinate information of four vertices of the quadrangle is read, a rotation angle of a scanning line for scanning each area with respect to the X axis is set, and an angle of a contour line of each area with respect to the positive direction of the X axis is calculated.
3. The laser powder bed melting arbitrary shape recognition and zoned scanning virtual printing method according to claim 1, wherein in S1, when the shape of the geometric model is a complex geometric body, an external stl model import method is adopted; for an stl geometric body input externally, firstly, setting a model value for each grid, wherein the initial model values are 0; when an stl geometric file is imported, setting the alpha value of a grid unit of the stl file in the model as 1; traversing all grids of the computational domain, and when the alpha of a grid = 1, making the model of the grid = 1; after the traversal is completed, let the substrate region alpha = 1 under the stl file to distinguish the metal region and the gas region of the calculation model.
4. The laser powder bed melting arbitrary shape recognition and regional scanning virtual printing method as claimed in claim 1, wherein two intersection points of a linear equation and a profile equation are an initial point and an end point of the scanning path respectively; the contour equation is a linear equation of straight lines AB, BC, CD and DA which are obtained by calculation of four vertexes A, B, C and D.
5. The method for virtual printing of arbitrary shape recognition and regional scanning of laser powder bed melting according to claim 1, wherein the scanning angle α and the scanning distance m between adjacent scanning tracks are determined according to the scanning angle α1The actual offset distance of the straight line along the Y-axis direction is calculated by:
6. the virtual printing method for arbitrary shape recognition and regional scanning during laser powder bed melting according to claim 1, wherein the formula for calculating the coordinates of the center position of the laser is as follows:
7. the method of claim 1, wherein the linear equation is shifted by a distance of m' in a positive direction along the Y axis to obtain a linear equation of the next scanning path:
8. the virtual printing method for arbitrary shape recognition and regional scanning of laser powder bed melting according to claim 1, wherein a regional printing algorithm is implanted in the thermal fluid model, and the algorithm realizes outline recognition and path planning of a polygon, so that the inside of an arbitrary quadrangle is filled, the outline is scanned, and virtual printing is realized.
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