CN113139314B - Heat source numerical simulation method for laser additive manufacturing process - Google Patents
Heat source numerical simulation method for laser additive manufacturing process Download PDFInfo
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Abstract
The invention provides a heat source numerical simulation method for a laser additive manufacturing process, which belongs to the technical field of process heat source numerical simulation and comprises the following steps: determining key parameters of a process molten pool area; constructing an initial heat source numerical model; calculating to obtain the calculated temperature distribution of a heat source of the laser additive manufacturing process and the geometric shape and size of the heat source; checking key parameters in the initial heat source numerical model to obtain an optimized heat source numerical model; and simulating to obtain the geometric shape and size of the heat source according to the optimized heat source numerical model. Through the design, the laser additive manufacturing process forming numerical calculation of various thicknesses and part sizes is realized, the calculation efficiency is improved, the process advantage is achieved, and the accuracy of establishing a process temperature field numerical simulation heat source model in laser additive manufacturing can be improved to the greatest extent.
Description
Technical Field
The invention belongs to the technical field of process heat source numerical simulation, and particularly relates to a heat source numerical simulation method for a laser additive manufacturing process.
Background
The additive manufacturing is a process for realizing the manufacturing of the three-dimensional part by controlling the material to be stacked layer by layer, compared with the traditional manufacturing mode, the additive manufacturing does not need an expensive mould, can greatly shorten the research and development period and the manufacturing cost, and can manufacture the part with a more complex shape. At present, the design and optimization of the process mainly depend on experience and multiple test verifications at home, and the foreign countries are biased to basic research and process numerical simulation. With the development and improvement of numerical simulation technology and additive manufacturing process, the requirement for the accuracy of the temperature field simulation of the manufacturing process is higher and higher in order to better evaluate the stress-strain distribution of the manufacturing process. Therefore, a reasonable heat source model and a reasonable calculation flow are basic conditions and important guarantees for realizing the additive manufacturing process simulation.
The additive manufacturing thermal cycle process is repeated and complex, the numerical simulation can be used as an effective technical means to analyze and research the thermal-force behavior of the additive manufacturing process, and the accuracy of the heat source model is the key to the success of the additive manufacturing numerical simulation. In the numerical simulation process of the existing additive manufacturing process, a general heat source model or an energy function is used for simplifying and replacing the simulation of a heat source, systematic characterization and construction are lacked, the calculation precision and efficiency are low, and the numerical calculation requirement of the additive manufacturing process cannot be met. In conclusion, the heat source simulation of the additive manufacturing process is the difficult point and the key point of the research in the engineering and scientific field at present.
Disclosure of Invention
Aiming at the defects in the prior art, the numerical simulation method for the process heat source for the laser additive manufacturing provided by the invention not only can improve the calculation efficiency, but also has the advantages of high efficiency and stability.
In order to achieve the above purpose, the invention adopts the technical scheme that:
the scheme provides a heat source numerical simulation method for a laser additive manufacturing process, which comprises the following steps:
s1, determining key parameters of a process molten pool area based on the distribution shape of the temperature field of the laser additive manufacturing part;
s2, constructing an initial heat source numerical model based on the laser additive manufacturing process characteristics and the geometric distribution structure of the heat source influence area;
s3, calculating to obtain heat source calculation temperature distribution and geometric shape and size of the heat source according to the initial heat source numerical model;
s4, checking the key parameters in the initial heat source numerical model according to the key parameters of the process molten pool area obtained in the step S1 and the calculation result of the step S3 to obtain an optimized heat source numerical model;
and S5, substituting the calculation step of the step S3 into the optimized heat source numerical model to calculate the geometric shape and size of the heat source, and completing the simulation of the heat source numerical value.
The invention has the beneficial effects that: the invention innovatively invents a heat source numerical calculation model aiming at the process aiming at the characteristics of the laser additive manufacturing process and the requirement of numerical simulation calculation, and defines the heat source calculation flow of the process model, so that the accurate heat source calculation model can be constructed and can be applied to the laser additive manufacturing process, and the numerical calculation of the laser additive process forming of various thicknesses and part sizes is realized.
Further, the expression of the heat source numerical model in step S2 is as follows:
wherein Q represents a heat source data model, Q 0 Representing the initial maximum input energy density, r i And r e Representing the radius of the bottom and top faces, R and R representing the radius of the laser additive powder and the heat source, respectively, z i And z e Respectively representing bottom and top coordinate values, x, y, z representing coordinate values of movement in three directions, t representing time, h representing height of the molten bath zone, y t+Δt 、y t 、z t+Δt And z t Y and z coordinate values, x, at times t + Δ t and t, respectively t+Δt And x t Respectively representing x-direction coordinate values at t + deltat and t, C representing an upper end heat source energy distribution coefficient, and r representing an upper end heat source radius.
The beneficial effects of the further scheme are as follows: a laser additive manufacturing process numerical simulation heat source model related to the thickness and the printing position of a test piece is defined.
Still further, the expression of the geometric dimension in step S3 is as follows:
wherein h is solver And w solver Respectively representing the depth and the width of a molten pool obtained by calculation, lambda represents the thermal conductivity of the material, A represents the section area of the test piece, T represents time, Q represents the energy of a heat source, and T represents the heat conductivity of the material h ，T w ，T 0 Respectively in the penetration directionAnd the temperature at a point in the melt width direction, i.e., the melt-depth and melt-width initiation temperatures.
The beneficial effects of the further scheme are as follows: a temperature field is calculated using the defined laser additive manufacturing process numerical simulation heat source model and calculated weld puddle depth and width values are determined.
Still further, the equation for checking in step S4 is:
h solver ＝h×k h
w solver ＝w×k w
wherein h is solver And w solver Respectively representing the calculated depth and width of the molten pool, k h And k w Respectively representing the sensitive coefficients of penetration and fusion width, h representing the actually measured molten pool depth, and w representing the actually measured molten pool width.
The beneficial effects of the further scheme are as follows: and comparing the depth and width values of the molten pool calculated by the numerical simulation heat source model of the defined laser additive manufacturing process with the actual measurement result to obtain the modification coefficients of the depth and the width direction of the molten pool.
Still further, the expression of the heat source numerical model optimized in step S4 is as follows:
wherein Q' represents the modified heat source numerical model, Q 0 Representing the initial maximum input energy density, r i And r e Representing the radius of the bottom and top faces, R and R representing the radius of the laser additive powder and heat source, respectively, z i And z e Respectively representing bottom and top coordinate values, x, y, z representing coordinate values of movement in three directions, t representing time, h representing height of the molten bath zone, y t+Δt 、y t 、z t+Δt And z t Y and z coordinate values, x, at times t + Δ t and t, respectively t+Δt And x t Respectively representing x-direction coordinate values at t + delta t and t, C representing the energy distribution coefficient of the upper-end heat source, r representing the radius of the upper-end heat source, k h And k w Respectively representing the penetration and the fusion width sensitivity coefficients.
The beneficial effects of the further scheme are as follows: and further modifying the numerical simulation heat source model of the laser additive manufacturing process according to the correction coefficient obtained from the measured value to obtain a heat source optimization numerical model for the laser additive manufacturing process.
Drawings
FIG. 1 is a flow chart of the method of the present invention.
Fig. 2 is a schematic diagram of a heat source model in this embodiment.
FIG. 3 is a schematic view of a bottom heat source model in this embodiment.
Detailed Description
The following description of the embodiments of the present invention is provided to facilitate the understanding of the present invention by those skilled in the art, but it should be understood that the present invention is not limited to the scope of the embodiments, and it will be apparent to those skilled in the art that various changes may be made without departing from the spirit and scope of the invention as defined and defined in the appended claims, and all matters produced by the invention using the inventive concept are protected.
Examples
Based on the defects of the prior art, the invention defines the process model heat source and the calculation flow thereof aiming at the laser additive manufacturing process characteristics and the numerical simulation calculation, so that the method can be applied to the laser additive manufacturing process and is suitable for the process forming numerical calculation of various thicknesses and part sizes, the method not only can improve the calculation efficiency, but also has the advantages of high efficiency and stability, and as shown in fig. 1, the method comprises the following steps:
s1, determining key parameters of a process molten pool area based on the distribution shape of the temperature field of the laser additive manufacturing part;
in the present example, as shown in FIG. 2, the key parameters include the depth of the molten pool (h), the width of the lower end of the molten pool (w) 1 ) And upper end width (w) 2 )。
S2, constructing an initial heat source numerical model based on the laser additive manufacturing process characteristics and the geometric distribution structure of the molten pool area, wherein the specific expression is as follows:
Q＝Q down +Q top (1)
wherein Q is an integral heat source; q down Is a bottom heat source; q top Is an upper end heat source.
According to the laser additive manufacturing process, the actual bottom heat source Q down A three-dimensional heat source signature is presented, as shown in fig. 3, while the local heat source is again related to print speed and spatial position, and therefore its functional expression is:
wherein Q is 0 Is the initial maximum input energy density; x, y and z are coordinate values of heat source movement along three directions; r is 0 Is the nominal radius of the bottom heat source; r is i ，r e Respectively the radius of the bottom end and the radius of the upper end surface; z is a radical of i And z e Coordinate values of the bottom end and the upper end of the heat source respectively; f (x, y, z, v) is a heat source coefficient of the laser additive manufacturing process; r and R are laser additive powder and heat source radius respectively; h represents the height of the molten pool zone; t is time; x is the number of t+Δt And x t X-direction coordinate values at t + delta t and t moment respectively; y is t+Δt 、y t 、z t+Δt 、z t Y and z coordinate values at t + Δ t and t time, respectively; c is the energy distribution coefficient of the upper end heat source; r is the upper heat source radius.
In summary, the initial heat source numerical model is:
s3, calculating to obtain heat source calculation temperature distribution and geometric shape and size of the heat source according to the initial heat source numerical model;
in this embodiment, formula (6) is discretely introduced into finite element software or programmed to perform calculation, so as to obtain a calculated temperature distribution of a heat source of a laser additive manufacturing process, complete calculation of the heat source of the additive manufacturing process, and obtain geometric shape and size of the heat source, such as penetration, fusion width, and the like, where:
wherein h is solver And w solver Respectively calculating the depth and the width of the molten pool; λ is the material thermal conductivity; a is the cross-sectional area of the test piece; t is time; q is heat source energy; t is h ，T w ，T 0 The temperatures at a certain point in the penetration direction and the melt width direction, and the initial temperatures of penetration and melt width, respectively.
S4, checking the key parameters in the initial heat source numerical model according to the key parameters of the process molten pool area obtained in the step S1 and the calculation result of the step S3 to obtain an optimized heat source numerical model;
in this embodiment, the penetration dimension is checked: obtaining the depth of a molten pool in the material welding process according to the calculation result of the formula (6), comparing the depth with the standard fusion depth obtained by testing in the step S1, and if the depth is smaller than the standard fusion depth, indicating that the energy or the size of the simulated heat source in the depth direction, namely the Z direction, is insufficient and needs to be increased; if the heat source size is larger than the predetermined value, the energy or size of the simulated heat source size in the depth direction, i.e., the Z direction, is too high and needs to be reduced.
In this embodiment, checking the fusion width size: obtaining the width of a molten pool in the material welding process according to the calculation result of the formula (6), and comparing the width with the standard molten width obtained in the test in S1 (the key parameters in the step S1 refer to the size of the molten pool, including the height (h) of the molten pool area and the width (w) of the lower end 1 ) And upper end width (w) 2 ) If the energy or the size of the simulated heat source is smaller than the preset value, the energy or the size of the simulated heat source in the width direction, namely the X direction, is not enough, and the simulated heat source needs to be increased; if the result exceeds the result of S1, the simulated heat source size becomes too high in energy or size in the X direction, which is the width direction, and needs to be reduced.
In the embodiment, according to the determination of the size of the molten pool depth and the molten pool width, the comprehensive comparison combination of the penetration depth and the penetration width can be comprehensively obtained, and the following equations are set up:
h solver ＝h×k h
w solver ＝w×k w
wherein k is h And k w Respectively, the penetration and the fusion width sensitivity coefficients. Thus, after optimization calculations, equation (6) can be expressed as:
in this embodiment, the actual geometric feature size of the heat source obtained in step S1 is compared with the calculation result for analysis, so as to check key parameters in the laser additive manufacturing heat source model and improve and refine the heat source numerical calculation model.
And S5, substituting the calculation step of the step S3 into the optimized heat source numerical model to calculate the geometric shape and size of the heat source, and completing the simulation of the heat source numerical value.
The invention innovatively invents a heat source numerical calculation model aiming at the process aiming at the characteristics of the laser additive manufacturing process and numerical simulation calculation, and defines a process model heat source calculation flow, so that the accurate heat source calculation model can be constructed and can be applied to the laser additive manufacturing process, the laser additive process forming numerical calculation of various thicknesses and part sizes is realized, and the heat source numerical model and the calculation flow can not only improve the calculation efficiency, but also have the advantages of flow, and can furthest improve the accuracy of the process temperature field numerical simulation heat source model establishment in the laser additive manufacturing.
Claims (2)
1. A heat source numerical simulation method for a laser additive manufacturing process is characterized by comprising the following steps of:
s1, determining key parameters of a process molten pool area based on the distribution shape of the temperature field of the laser additive manufacturing part;
s2, constructing an initial heat source numerical model based on the laser additive manufacturing process characteristics and the geometric distribution structure of the molten pool area;
s3, calculating to obtain heat source calculation temperature distribution and geometric shape and size of the heat source according to the initial heat source numerical model;
s4, checking the key parameters in the initial heat source numerical model according to the key parameters of the process molten pool area obtained in the step S1 and the calculation result of the step S3 to obtain an optimized heat source numerical model;
s5, substituting the calculation step of the step S3 into the optimized heat source numerical model to calculate the geometric shape and size of the heat source, and completing the simulation of the heat source numerical value;
the expression of the geometric dimension in step S3 is as follows:
wherein h is solver And w solver Respectively representing the depth and width values of the molten pool obtained by calculation, wherein lambda represents the thermal conductivity of the material, A represents the section area of the test piece, T represents time, Q represents the energy of a heat source, and T represents the heat conductivity of the material h ，T w ，T 0 Respectively representThe temperature at a certain point in the penetration direction and the fusion width direction, namely the initial temperature of penetration and fusion width;
the equation for checking in step S4 is:
h solver ＝h×k h
w solver ＝w×k w
wherein h is solver And w solver Respectively representing the calculated depth and width of the molten pool, k h And k w Respectively representing the sensitive coefficients of penetration depth and penetration width, h representing the height of a molten pool area, and w representing the width of the molten pool area;
the expression of the heat source numerical model optimized in step S4 is as follows:
wherein Q' represents the modified heat source numerical model, Q 0 Representing the initial maximum input energy density, r i And r e Representing the radius of the bottom and top faces, R and R representing the radius of the laser additive powder and the heat source, respectively, z i And z e Respectively representing bottom and top coordinate values, x, y, z representing coordinate values of movement in three directions, t representing time, h representing height of the molten pool area, y t+Δt 、y t 、z t+Δt And z t Y and z coordinate values, x, at times t + Δ t and t, respectively t+Δt And x t Respectively representing x-direction coordinate values of t + deltat and t time, C representing the energy distribution coefficient of the upper-end heat source, r representing the radius of the upper-end heat source, k h And k w Respectively representing the penetration and the fusion width sensitivity coefficients.
2. The heat source numerical simulation method for the laser additive manufacturing process according to claim 1, wherein the expression of the heat source numerical model in the step S2 is as follows:
wherein Q represents a heat source data model, Q 0 Representing the initial maximum input energy density, r i And r e Representing the radius of the bottom and top faces, R and R representing the radius of the laser additive powder and the heat source, respectively, z i And z e Respectively representing bottom and top coordinate values, x, y, z representing coordinate values of movement in three directions, t representing time, h representing height of the molten bath zone, y t+Δt 、y t 、z t+Δt And z t Y and z coordinate values, x, at times t + Δ t and t, respectively t+Δt And x t Respectively representing x-direction coordinate values at t + deltat and t, C representing an upper end heat source energy distribution coefficient, and r representing an upper end heat source radius.
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