CN113343521B - Method for predicting interlayer thermal stress distribution in selective laser melting process based on COMSOL - Google Patents
Method for predicting interlayer thermal stress distribution in selective laser melting process based on COMSOL Download PDFInfo
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- B33Y50/00—Data acquisition or data processing for additive manufacturing
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Abstract
The application provides a method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL, which comprises the following steps: s1: constructing a three-dimensional solid heat transfer and structural mechanics transient model based on COMSOL; s2: determining parameters in the simulation process; s3: determining a material property of the powder to be melted; s4: determining a moving Gaussian heat source parameter; s5: constructing a geometric model of the powder bed; s6: realizing layer-by-layer manufacture of selective laser melting; s7: dividing grids and calculating node temperatures; s8: and predicting interlayer thermal stress distribution and residual thermal stress distribution according to the result of the step S7. According to the method, the laser heat source effect in the machining process is simulated through the moving Gaussian heat source die, and a uniform material powder bed is utilized to replace the powder bed; in addition, the structural mechanical module is utilized to simulate the thermal stress and the deformation condition of a workpiece generated by the layer when moving along with a heat source, and simulate the layer-by-layer manufacturing process of the selective laser melting technology, so that the prediction of multi-layer thermal stress and residual thermal stress is realized.
Description
Technical Field
The invention relates to the technical field of thermal stress distribution, in particular to a method for predicting interlayer thermal stress distribution in a selective laser melting technology based on COMSOL.
Background
The selective laser melting technology is a near net shape forming technology based on material discrete-gradual accumulation mode to manufacture solid parts. The technology generally takes metal powder as a raw material, sets a laser scanning path through three-dimensional model pre-layering treatment, adopts high-energy laser beams to melt the metal powder layer by layer according to the set scanning path, and enables the metal powder to be quickly solidified and stacked to form a high-performance component. During laser melting techniques, metallic materials undergo rapid heating, solidification, and cooling processes, during which large thermal stresses and tissue stresses caused by solid state phase changes are created. These stresses remain inside the workpiece after the completion of forming, and become residual stresses. If the residual stress exceeds the yield strength of the material itself, the formed article is deformed, resulting in a decrease in dimensional accuracy and workability. Therefore, the deformation of the additive manufacturing metal parts is always one of research hotspots in the field of additive manufacturing at home and abroad. The existing method for predicting the thermal stress between layers in the manufacturing process of the laser melting technology is a volumetric heat source method, namely, each layer generates a slice entity and is provided with a volumetric heat source, so that the distribution of the thermal stress between layers is predicted, such as the existing additive manufacturing plate newly added by ANSYS. However, when the volumetric heat source is loaded on each slice layer, only the thermal stress distribution between layers can be predicted, and the distribution of the thermal stress accumulated in each layer in a single scanning process cannot be accurately predicted.
Therefore, a method for accurately predicting the cumulative occurrence of thermal stress on each layer by a single scan is needed.
Disclosure of Invention
In view of the above, the present invention provides a method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL, which is characterized in that: the method comprises the following steps:
s1: constructing a three-dimensional solid heat transfer and structural mechanics transient model based on COMSOL;
s2: parameters in the simulation process are determined, wherein the parameters comprise a scanning interval D_spot, a laser scanning speed v_spot, a laser power P_laser, a laser radius r_spot, a surface emissivity A_Gass, a powder accumulation rate w_powder and a powder layer thickness;
s3: determining material properties of the powder to be melted, the material properties including thermal conductivity, specific heat capacity, material density, coefficient of thermal expansion, young's modulus, and poisson's ratio;
s4: determining a moving gaussian heat source parameter, wherein the moving gaussian heat source parameter comprises the number of the moving gaussian heat sources, and each moving gaussian heat source uses a time-dependent difference function;
s5: constructing a geometric model of the powder bed, and determining initial conditions, boundary heat source conditions and boundary conditions under solid mechanical nodes of the geometric model of the powder bed;
s6: realizing layer-by-layer manufacture of selective laser melting;
s7: performing grid division on a geometric model of the powder bed and determining the temperature, stress and strain of the nodes; the temperature, stress and strain of the nodes are determined by energy conservation and stress balance through meshing.
S8: and predicting interlayer thermal stress distribution and residual thermal stress distribution according to the result of the step S7.
Further, step S3 also includes pretreating the shape of the powder material to be melted deposited on the powder bed, i.e., pretreating the bulk density of the powder, for approximating the powder bed of the powder deposit to a rectangular parallelepiped.
Further, the bulk density of the powder is 40% -60%.
Further, the powder bulk density was 50%.
Further, in step S4, the number of the moving gaussian heat sources is determined according to the slice shape, the scanning pitch and the laser radius, so that one tiling scan can cover the target slice shape.
Further, the difference function in step S4 is determined by the following method:
x_focus＝x_f1(t) (1)
where x denotes an x direction in which the gaussian heat source moves, x_focus denotes a focal point of the gaussian heat source in x direction, and x_f1 (t) denotes a function of the x direction in which the gaussian heat source moves;
y_focus＝y_f1(t) (2)
wherein y represents the y direction of movement of the gaussian heat source, y_focus represents the focal point of the gaussian heat source in the y direction, and y_f1 (t) represents a function of the y direction of movement of the gaussian heat source;
r_focus＝sqrt((x-x_focus)∧2+(y-y_focus)∧2) (3)
wherein r_focus represents the focus of the gaussian heat source, the focus is determined by the x-direction and the y-direction focus of the gaussian heat source, x represents the x-direction of the gaussian heat source movement, x_focus represents the x-direction focus of the gaussian heat source, y represents the y-direction of the gaussian heat source movement, and y_focus represents the y-direction focus of the gaussian heat source;
Flux＝((2*A_Gass*P_laser)/(pi*r_spot∧2))*exp(-2*r_focus∧2)/r_spot∧2)(4)
wherein Flux represents the heat Flux of the Gaussian heat source, A_Gass represents the absorptivity of the material, P_laser represents the laser heat source, pi represents pi, r_spot represents the laser radius, and r_focus represents the focal point of the Gaussian heat source.
The beneficial technical effects of the invention are as follows: according to the method, through a moving Gaussian heat source model, the influence of heat radiation and natural convection on the surface of a material on a temperature field is considered, the laser heat source effect in the processing process is simulated, and the material property is approximately processed, so that a uniform material powder bed is utilized to replace the powder bed; in addition, when the structural mechanical module is used for simulating the thermal stress and the deformation condition of a workpiece generated by the layer along with the movement of a heat source, and finally, an activation method is used for simulating the layer-by-layer manufacturing process of the selective laser melting technology, so that the prediction of the thermal stress and the residual thermal stress between multiple layers and the influence of the laser action effect of a rear layer on a front layer are realized.
Drawings
The invention is further described below with reference to the accompanying drawings and examples:
fig. 1 is a flow chart of the present application.
Fig. 2 is a grid section of the present application.
FIG. 3 is a schematic diagram of the temperature and stress fields of the present application.
Detailed Description
The invention is further described below with reference to the accompanying drawings of the specification:
the invention provides a method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL, which is characterized by comprising the following steps of: the method comprises the following steps: as shown in figure 1 of the drawings,
s1: constructing a three-dimensional solid heat transfer and structural mechanics transient model based on COMSOL;
s2: parameters in the simulation process are determined, wherein the parameters comprise a scanning interval D_spot, a laser scanning speed v_spot, a laser power P_laser, a laser radius r_spot, a surface emissivity A_Gass, a powder accumulation rate w_powder and a powder layer thickness;
s3: determining material properties of the powder to be melted, the material properties including thermal conductivity, specific heat capacity, material density, coefficient of thermal expansion, young's modulus, and poisson's ratio;
s4: determining a moving gaussian heat source parameter, wherein the moving gaussian heat source parameter comprises the number of the moving gaussian heat sources, and each moving gaussian heat source uses a time-dependent difference function;
s5: constructing a geometric model of the powder bed, and determining initial conditions, boundary heat source conditions and boundary conditions under solid mechanical nodes of the geometric model of the powder bed;
the initial conditions, boundary heat source conditions and boundary conditions under the determined solid mechanics nodes of the geometric model are as follows:
solid heat transfer
1. To simulate the preheating effect of the substrate, all initial temperatures were defined as 35degC, all surfaces of the model were defined with a heat transfer coefficient of 80W/(m2.K), and the boundary conditions of convective heat flux simulated the influence of the wind field on the process.
2. Secondly, the surface of the material acted by the laser is defined as the boundary condition of the surface to the environmental radiation, and the heat exchange process between the surface of the high-temperature material and the environment is simulated under the action of a moving Gaussian heat source.
3. Next, a time dependent gaussian heat source is defined for each layer of material to simulate the loading of the heat source.
Solid mechanics
1. A boundary condition of a fixed constraint is imposed on the bottom surface of the substrate to prevent deformation in this direction.
2. Thermal expansion nodes are added to the material that is exposed to the laser.
3. To achieve layer-by-layer fabrication, a time-dependent activation expression is used, with an activation scale factor set to 1e-5.
S6: realizing layer-by-layer manufacture of selective laser melting; each layer uses a "zig" scanning strategy, three times in total, to simulate laser continuous processing, where each layer is lased for a total duration of t_x= 0.00116s, taking into account a cooling time of 0.2 x t_x, and then activating the next powder bed.
S7: performing grid division on a geometric model of the powder bed and determining the temperature, stress and strain of the nodes; the temperature, stress and strain of the nodes are determined by energy conservation and stress balance through meshing. The method is modeling, and simple grid division is carried out on the model to achieve corresponding effects. The lower diagram is a grid cut-away diagram, and the order of layer-by-layer fabrication. As shown in fig. 2.
S8: and predicting interlayer thermal stress distribution and residual thermal stress distribution according to the result of the step S7. As shown in fig. 3. Step S8 characterizes the result according to the target physical quantity by utilizing the function of "post-processing" of the COMSOL software. And S7, dividing the powder bed by using finite elements, namely, dividing the powder bed into zero, determining the temperature, the stress and the strain of each node, and S8, integrating the calculation result set of each node into zero, and obtaining the temperature, the stress and the strain of the powder bed from the whole angle of the powder bed through a software post-processing function, thereby realizing the prediction of the interlayer thermal stress and the residual thermal stress. If the stress is taken as an example, a three-dimensional stress checking node is established under the result node, the expected result can be obtained by inputting an expression, and the temperature and the strain can be checked in the same way, and the description is omitted here.
According to the technical scheme, the effect of a laser heat source in the processing process is simulated by taking the phase change of a material into consideration and the influence of heat radiation and natural convection on the surface of the material on a temperature field, and the uniform material powder bed is utilized to replace the powder bed by performing approximate treatment on the material property; in addition, when the structural mechanical module is used for simulating the thermal stress and the deformation condition of a workpiece generated by the layer along with the movement of a heat source, and finally, an activation method is used for simulating the layer-by-layer manufacturing process of the selective laser melting technology, so that the prediction of the thermal stress and the residual thermal stress between multiple layers and the influence of the laser action effect of a rear layer on a front layer are realized.
In this embodiment, step S3 further includes pre-treating the shape of the powder material to be melted deposited on the powder bed, i.e., pre-treating the bulk density of the powder, for approximating the powder bed of the powder deposit as a rectangular parallelepiped. Because the method is used for predicting the interlayer thermal stress and can not characterize the physical phenomenon of the melting process, the method predicts the thermal stress by using a more regular powder bed after melting, and regards the powder bed as a regular cuboid for approximate treatment and reducing calculation difficulty.
In this embodiment, the bulk density of the powder is in the range of 40% to 60%. The powder bulk density was 50%. In the powder bed modeling process, hundreds or thousands of powder balls are piled on the powder bed, pores exist between the powder balls, the loose packing density reflects the porosity of the powder bed, and the loose packing density is taken to be 50% in the embodiment so as to simulate the piling effect of the powder bed.
In this embodiment, the number of the gaussian heat sources is determined in step S4 according to the slice shape, the scanning pitch and the laser radius, so that one tiling scan can cover the target slice shape. The determination of the number of gaussian heat sources is shown as an example: modeling each layer of powder bed according to a regular model, wherein the length and the times of Gaussian heat source scanning depend on the shape of each layer of slice, the slice is a regular rectangle, and the regular cuboid in the case can be scanned by three times of scanning under the preset scanning interval and laser radius. One skilled in the art can determine the number of gaussian heat sources based on the actual slice, scan pitch, and laser radius.
In this embodiment, the difference function in step S4 is determined by the following method:
x_focus＝x_f1(t) (1)
where x denotes an x direction in which the gaussian heat source moves, x_focus denotes a focal point of the gaussian heat source in x direction, and x_f1 (t) denotes a function of the x direction in which the gaussian heat source moves;
y_focus＝y_f1(t) (2)
wherein y represents the y direction of movement of the gaussian heat source, y_focus represents the focal point of the gaussian heat source in the y direction, and y_f1 (t) represents a function of the y direction of movement of the gaussian heat source;
r_focus＝sqrt((x-x_focus)∧2+(y-y_focus)∧2) (3)
wherein r_focus represents the focus of the gaussian heat source, the focus is determined by the x-direction and the y-direction focus of the gaussian heat source, x represents the x-direction of the gaussian heat source movement, x_focus represents the x-direction focus of the gaussian heat source, y represents the y-direction of the gaussian heat source movement, and y_focus represents the y-direction focus of the gaussian heat source;
Flux＝((2*A_Gass*P_laser)/(pi*r_spot∧2))*exp(-2*r_focus∧2)/r_spot∧2)(4)
wherein Flux represents the heat Flux of the Gaussian heat source, A_Gass represents the absorptivity of the material, P_laser represents the laser heat source, pi represents pi, r_spot represents the laser radius, and r_focus represents the focal point of the Gaussian heat source.
Finally, it is noted that the above embodiments are only for illustrating the technical solution of the present invention and not for limiting the same, and although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications and equivalents may be made thereto without departing from the spirit and scope of the technical solution of the present invention, which is intended to be covered by the scope of the claims of the present invention.
Claims (6)
1. A method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL is characterized by comprising the following steps: the method comprises the following steps:
s1: constructing a three-dimensional solid heat transfer and structural mechanics transient model based on COMSOL;
s2: parameters in the simulation process are determined, wherein the parameters comprise a scanning interval D_spot, a laser scanning speed v_spot, a laser power P_laser, a laser radius r_spot, a surface emissivity A_Gass, a powder accumulation rate w_powder and a powder layer thickness;
s3: determining material properties of the powder to be melted, the material properties including thermal conductivity, specific heat capacity, material density, coefficient of thermal expansion, young's modulus, and poisson's ratio;
s4: determining a moving gaussian heat source parameter, wherein the moving gaussian heat source parameter comprises the number of the moving gaussian heat sources, and each moving gaussian heat source uses a time-dependent difference function;
s5: constructing a geometric model of the powder bed, and determining initial conditions, boundary heat source conditions and boundary conditions under solid mechanical nodes of the geometric model of the powder bed; comprising the following steps:
solid heat transfer
All initial temperatures are defined as 35degC, all surfaces of the model are defined as heat transfer coefficients of 80W/(m < 2 >. K), and boundary conditions of convection heat flux simulate the influence of a wind field on processing in the processing process;
the surface of the material acted by the laser is defined as the boundary condition of the surface to the environmental radiation, and the heat exchange process between the surface of the high-temperature material and the environment is simulated under the action of a moving Gaussian heat source;
defining a time dependent gaussian heat source for each layer of material to simulate loading of the heat source;
solid mechanics
Applying a boundary condition of fixed constraint to the bottom surface of the substrate to prevent deformation in this direction;
adding thermal expansion nodes to the material acted by the laser;
using a time dependent activation expression, the activation scale factor is set to 1e-5;
s6: realizing layer-by-layer manufacture of selective laser melting;
s7: performing grid division on a geometric model of the powder bed and determining the temperature, stress and strain of the nodes; determining the temperature, stress and strain of the node through energy conservation and stress balance by grid division;
s8: and predicting interlayer thermal stress distribution and residual thermal stress distribution according to the result of the step S7.
2. The method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL according to claim 1, wherein the method comprises the following steps of: step S3 further comprises pre-treating the shape of the powder material to be melted deposited on the powder bed, i.e. the bulk density of the powder, for approximating the powder bed of the powder deposit as a cuboid.
3. The method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL according to claim 2, wherein the method comprises the following steps of: the bulk density of the powder is 40% -60%.
4. A method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL according to claim 3, wherein: the powder bulk density was 50%.
5. The method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL according to claim 1, wherein the method comprises the following steps of: in the step S4, the number of the mobile Gaussian heat sources is determined according to the slice shape, the scanning interval and the laser radius, so that the target slice shape can be covered by one tiling scanning.
6. The method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL according to claim 1, wherein the method comprises the following steps of: the difference function in step S4 is determined by the following method:
x_focus＝x_f1(t) (1)
where x denotes an x direction in which the gaussian heat source moves, x_focus denotes a focal point of the gaussian heat source in x direction, and x_f1 (t) denotes a function of the x direction in which the gaussian heat source moves;
y_focus＝y_f1(t) (2)
where y represents the y direction of movement of the gaussian heat source, y_focus represents the focal point of the y-direction gaussian heat source, and y_f1 (t) represents the function of the y direction of movement of the gaussian heat source;
r_focus＝sqrt((x-x_focus)^2+(y-y_focus)^2) (3)
wherein r_focus represents the focus of the gaussian heat source, the focus is determined by the x-direction and the y-direction focus of the gaussian heat source, x represents the x-direction of the gaussian heat source movement, x_focus represents the x-direction focus of the gaussian heat source, y represents the y-direction of the gaussian heat source movement, and y_focus represents the y-direction focus of the gaussian heat source;
Flux＝((2*A_Gass*P_laser)/(pi*r_spot^2))*exp(-2*r_focus^2)/r_spot^2)(4)
wherein Flux represents the heat Flux of the Gaussian heat source, A_Gass represents the absorptivity of the material, P_laser represents the laser heat source, pi represents pi, r_spot represents the laser radius, and r_focus represents the focal point of the Gaussian heat source.
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| CN113976920B (en) * | 2021-09-27 | 2022-08-26 | 上海交通大学 | Cross-scale control method and system for residual deformation of selective laser melting forming structure |
| CN113779906B (en) * | 2021-11-12 | 2022-02-11 | 北京科技大学 | Method for calculating denitrification dynamics in vacuum induction melting process of nickel-based superalloy |
| CN116275125B (en) * | 2023-05-19 | 2023-09-01 | 西北工业大学 | Method for predicting formation and distribution characteristics of additive manufacturing molten pool |
| CN116680962B (en) * | 2023-08-01 | 2023-10-17 | 北京理工大学 | Method for predicting surface quality and residual stress of formed part under selective laser melting technology |
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