CN113399682B - Intelligent thin-wall structure additive manufacturing accurate shape control method based on dynamic compensation strategy - Google Patents

Intelligent thin-wall structure additive manufacturing accurate shape control method based on dynamic compensation strategy Download PDF

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CN113399682B
CN113399682B CN202110677733.9A CN202110677733A CN113399682B CN 113399682 B CN113399682 B CN 113399682B CN 202110677733 A CN202110677733 A CN 202110677733A CN 113399682 B CN113399682 B CN 113399682B
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CN113399682A (en
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韦辉亮
刘婷婷
廖文和
刘福钦
张昌春
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Nanjing University of Science and Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • 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
    • B33Y10/00—Processes of additive manufacturing
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

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Abstract

The invention discloses a dynamic compensation strategy-based intelligent material increase manufacturing accurate shape control method for a thin-wall structure, which comprises the following steps: establishing a fluid mechanics model of the thin-wall structure; step two: establishing a control equation of a fluid mechanics model; step three: printing the thin-wall structure of the same starting point of each layer according to the control equation in the second step; step four: and D, changing a scanning strategy according to the thin-wall structure shape obtained in the step three, and carrying out intelligent shape control on the thin-wall structure. The scanning strategy of the invention can avoid the phenomenon of unevenness generated in the forming process of the thin-wall cylinder, and the invention can also repair parts when the uneven surface is generated, thereby promoting the further development of the laser directional energy deposition technology.

Description

Intelligent thin-wall structure additive manufacturing accurate shape control method based on dynamic compensation strategy
Technical Field
The invention belongs to the technical field of laser additive manufacturing and rapid forming, particularly relates to a printing quality control method for a thin-wall structure, and particularly relates to an intelligent additive manufacturing accurate shape control method for the thin-wall structure based on a dynamic compensation strategy.
Background
With the continuous development of scientific technology, the additive manufacturing technology also enters a brand new stage, and the laser directional energy deposition technology is an important component of the laser additive manufacturing technology, mainly takes metal powder as a raw material, melts the metal powder synchronously sent out by a nozzle by using laser, deposits the metal powder on a metal substrate, and then cumulatively stacks layer by layer to form a target component. Laser
The photo-directed energy deposition technique has the following advantages:
(1) the complex metal parts can be printed without the support of a die.
(2) Compared with a selective laser melting technology, the printable part of the directional laser energy deposition technology has a larger size.
(3) The damaged parts can be directly repaired by utilizing a laser directional energy deposition technology.
Laser directed energy deposition is a multi-physical field, multi-scale process accompanied by multiple energy changes, and different input parameters have great influence on the shape, quality, size and the like of a finally formed part. In the laser directional energy deposition process, besides basic input parameters, different scanning strategies also have great influence on the forming quality of parts, and the same scanning parameter cannot be simultaneously applied to forming parts with different structures.
For the circular scanning strategy, in the process of printing a thin-wall structure, due to the interaction of various forces in the molten pool, the fluid in the molten pool can flow back to form a bulge at the initial part, and can shrink and become flat at the end, which is an important factor influencing the printing quality of the thin wall. The phenomenon can cause the surface of the formed thin-wall structure to have an uneven phenomenon, and the performance of the finally formed part is greatly influenced, so that the further development of the laser directional energy deposition technology is severely limited.
Disclosure of Invention
The invention aims to solve the technical problem of the prior art, provides an intelligent material increase manufacturing accurate shape control method for a thin-wall structure based on a dynamic compensation strategy, and can overcome the defect of thin-wall structure forming quality caused by a scanning strategy.
In order to achieve the technical purpose, the technical scheme adopted by the invention is as follows:
a thin-wall structure intelligent additive manufacturing accurate shape control method based on a dynamic compensation strategy is characterized by comprising the following steps:
the method comprises the following steps: establishing a fluid mechanics model of the thin-wall structure;
step two: establishing a control equation of a fluid mechanics model;
step three: printing the thin-wall structure of the same starting point of each layer according to the control equation in the second step;
Step four: and changing a scanning strategy according to the thin-wall cylindrical shape obtained in the step three, and carrying out intelligent shape control on the thin-wall structure.
In order to optimize the technical scheme, the specific measures adopted further comprise:
the first step is specifically as follows: establishing a fluid mechanics model of a thin-wall structure, dividing grids, defining material thermophysical properties, and initializing the model;
in the second step, the control equation comprises an energy conservation equation, a mass conservation equation and a momentum conservation equation;
conservation of mass equation:
Figure BDA0003121530460000021
the conservation of momentum equation:
Figure BDA0003121530460000022
energy conservation equation:
Figure BDA0003121530460000023
phase equation:
Figure BDA0003121530460000024
where p is the density of the material,
Figure BDA0003121530460000025
is the velocity vector, t is time, p is pressure, μ is dynamic viscosity,
Figure BDA0003121530460000026
in order to be a momentum source term,
Figure BDA0003121530460000027
in order to be the marangoni force,
Figure BDA0003121530460000028
in order to be a surface tension force,
Figure BDA0003121530460000029
in order to be a buoyancy force,
Figure BDA00031215304600000210
damping force in the mushy zone, T is temperature, C p Is specific heat capacity, k is thermal conductivity, S T Is an energy source term, Q h Is surface heat, Q l Is the energy lost due to thermal convection, thermal radiation and evaporation.
In the second step, the heat source used by the model is a gaussian heat source:
Figure BDA00031215304600000211
wherein f is a distribution factor, eta is an absorption rate, P is laser power, r is a laser radius, (x) 0 ，y 0 ) Is the laser beam center coordinate;
The initial temperature set was 298K, and the temperature boundary conditions were:
T(x，y，z，0)＝T 0 (x，y，z) (6)
the speed boundary condition is set to 0 at each boundary.
In the fourth step, when the height difference between the head and the tail of the thin-wall structure obtained in the third step is greater than the set threshold, scanning strategies of 60-degree deflection and 180-degree deflection between adjacent layers are selected.
In the fourth step, when the surface undulation of the thin-wall structure obtained in the third step is larger than a set threshold value, a scanning strategy that adjacent layers scan clockwise and counterclockwise respectively is adopted.
In the fourth step, when the thin-wall structure obtained in the third step has a fluctuating phenomenon at a specific position, a scanning strategy that each layer deflects by a random angle is adopted.
In the fourth step, when the unevenness at the beginning and the end of the thin-wall structure scanning obtained in the third step exceeds the set condition, a scanning strategy which changes periodically is adopted.
The above-mentioned periodically varying scan strategy is:
the first cycle start point is 0 degrees, each layer is spaced by 60 degrees, the second cycle start point is 30 degrees, each layer is spaced by 60 degrees, and then the two cycles are repeated;
or the like, or, alternatively,
the first cycle start point is 0 degrees, each layer is spaced 60 degrees apart, the second cycle start point is 30 degrees, each layer is spaced 60 degrees apart, the third cycle start point is 0 degrees, each layer is spaced 90 degrees apart, the fourth cycle start point is 45 degrees, each layer is spaced 90 degrees apart, and then the four cycles are repeated.
In the fourth step, the height difference in the deposition process in the third step is monitored in real time, so that the starting point of the next layer is located in the depression area, and the depression is compensated, wherein the height difference refers to the difference between the maximum height and the minimum height of the top surface of the thin-wall structure from the surface of the substrate.
The invention has the following beneficial effects:
the scanning strategy of the invention can avoid the phenomenon of unevenness generated in the forming process of the thin-wall structure, and the invention can also repair parts when the uneven surface is generated, thereby promoting the further development of the laser directional energy deposition technology.
Drawings
Fig. 1 shows thin-walled cylindrical views of (a) the 15 th layer and (b) the 30 th layer from the same starting point for each layer.
FIG. 2 is a thin-walled cylinder view of the layers 180 degrees offset from the previous layer (a) layer 12 and (b) layer 24.
FIG. 3 is a thin-walled cylinder of the layers 60 ° offset from the previous layer (a) layer 12, (b) layer 24.
Fig. 4 is a thin-walled cylinder diagram of (a) 12 th layer, (b) 24 th layer from the same starting point of each layer, with adjacent layers scanned clockwise and counterclockwise.
Fig. 5 is a thin-walled cylinder view of (a) layer 12 and (b) layer 24, with adjacent layers scanned clockwise and counterclockwise, with the subsequent layer being 180 ° offset from the previous layer.
FIG. 6 is a thin-walled cylinder of layers deflected by random angles (a) layer 12 and (b) layer 24.
Fig. 7 is a thin-walled cylinder diagram employing a periodically varying scanning strategy, (a) first cycle, (b) second cycle, (c) layer 12, (d) layer 24.
FIG. 8 is a thin-walled cylinder diagram employing a periodically varying scanning strategy, (a) a first cycle (b) a second cycle, (c) a third cycle (d) a fourth cycle, (e) layer 12 (f) layer 24;
FIG. 9 is a flow chart of an intelligent shape control method for additive manufacturing of a thin-wall structure based on a dynamic compensation strategy.
Detailed Description
Embodiments of the present invention are described in further detail below with reference to the accompanying drawings.
Referring to fig. 9, a method for accurately controlling shape of a thin-wall structure in intelligent additive manufacturing based on a dynamic compensation strategy includes:
the method comprises the following steps: taking a thin-wall cylinder as an example, a hydrodynamic model of a resume thin-wall structure specifically comprises the following steps:
establishing a fluid mechanics model of the thin-wall cylinder, dividing grids, defining the thermophysical properties of the material, and initializing the model;
the model adopts Ti-6Al-4V as a deposition material, and the physical parameters of Ti-6Al-4V powder and the technological parameters of laser directional energy deposition of Ti-6Al-4V are shown in tables 1 and 2. The size of the metal substrate used is 20mm × 20mm × 4mm, the mesh size of the deposition area is 0.25mm × 0.25mm × 0.25mm, the radius of the thin-walled cylinder is 15mm, and the total number of layers deposited is 24.
TABLE 1 physical Properties of Ti-6Al-4V powder
Figure BDA0003121530460000041
TABLE 2 laser directional energy deposition Ti-6Al-4V Process parameters
Figure BDA0003121530460000042
Step two: establishing a control equation of a fluid mechanics model;
within the scope of computational fluid dynamics, the flow of any one object must obey the laws of conservation of momentum, conservation of mass and conservation of energy,
the control equation comprises an energy conservation equation, a mass conservation equation and a momentum conservation equation;
conservation of mass equation:
Figure BDA0003121530460000051
conservation of momentum equation:
Figure BDA0003121530460000052
energy conservation equation:
Figure BDA0003121530460000053
phase equation:
Figure BDA0003121530460000054
where p is the density of the material,
Figure BDA0003121530460000055
is the velocity vector, t is time, p is pressure, μ is dynamic viscosity,
Figure BDA0003121530460000056
in order to be a momentum source term,
Figure BDA0003121530460000057
in order to be the marangoni force,
Figure BDA0003121530460000058
in order to be a surface tension force,
Figure BDA0003121530460000059
in order to be a buoyancy force,
Figure BDA00031215304600000510
damping force in the mushy zone, T is temperature, C p Is specific heat capacity, k is thermal conductivity, S T Is an energy source term, Q h Is surface heat, Q l Is the energy lost due to thermal convection, thermal radiation and evaporation.
The three control methods control the state of fluid motion, equations describing the fluid motion are derived according to the conservation laws, continuity equations in fluid mechanics can be derived according to the conservation law of mass, Navier-Stokes equations for controlling the fluid motion can be derived according to the conservation of momentum, and state equations for fluid flow can be derived according to the conservation of energy. The phase equation controls two different states, namely, whether the material is in a metal phase or a gas phase.
The heat source used by the model is a gaussian heat source:
Figure BDA00031215304600000511
wherein f is a distribution factor, eta is an absorption rate, P is laser power, r is a laser radius, (x) 0 ，y 0 ) Is the laser beam center coordinate.
The setting of the initial conditions and the boundary conditions includes both the temperature field and the velocity field.
In order to reasonably solve the temperature control equation, initial conditions are set according to the characteristics of the formation in the heat transfer process, wherein the set initial temperature is 298K, and the temperature boundary conditions are as follows:
T(x，y，z，0)＝T 0 (x，y，z) (6)
the speed boundary condition is set to 0 at each boundary.
The equations (1) - (4) control the motion and state of the fluid, while the equation (5) prescribes the state of the laser heat source, the laser heat source acts on the metal powder, when the melting point of the metal powder is reached, the metal powder is subjected to solid-liquid phase change, the solid is changed into liquid, and then the control equation controls the state of the liquid flow.
Step three: and (3) performing thin-wall cylinder printing at the same starting point of each layer according to the control equation of the second step, and printing thin-wall cylinders of 15 layers and 30 layers as shown in fig. 1(a) and (b), wherein a large height difference exists at the starting position and the ending position, and the height difference is continuously increased along with the increase of the number of layers.
Step four: changing a scanning strategy according to the appearance of the thin-wall cylinder obtained in the third step, and performing intelligent shape control on the thin-wall cylinder, wherein the method comprises the following steps:
1. and selecting scanning strategies of deflecting 60 degrees and 180 degrees between adjacent layers according to the condition that the large height difference occurs between the head and the tail of the thin-wall cylinder in the third step.
When the adjacent layers deflect by 180 degrees, because the beginning and the end of the deposition track generate height difference, two larger pits are finally formed on two sides of the thin-wall cylinder, and the height difference of the two pits is reduced relative to the height difference of the thin-wall cylinder printed at the same starting point of each layer, as shown in fig. 2;
on the basis, the deflection angle between adjacent layers is further reduced, and a scanning strategy of deflecting 60 degrees between adjacent layers is adopted, as shown in figure 3, it can be seen that when the number of deposited layers is increased, the height difference of the surface of the thin-wall cylinder is further reduced, and a relatively flat thin-wall cylinder can be printed.
2. Considering that the surface of a printed thin-wall cylinder has larger undulation when scanning in the same direction, a scanning strategy that adjacent layers scan clockwise and anticlockwise respectively is adopted.
When the layers have the same starting point, the formed thin-walled cylinder is as shown in fig. 4, and it can be seen that the formed thin-walled cylinder has better quality than the cylinder formed by scanning in the same direction, but the protrusions at the starting point of each layer are overlapped with each other, and finally the protrusions at the starting point are slightly more than those at other positions.
When the adjacent layers are deflected by 180 degrees, the formed thin-wall cylinder has better quality compared with the thin-wall cylinder formed by scanning in the same direction, but a certain height difference can be formed at two starting points of the thin-wall cylinder, so that the surface of the thin-wall cylinder has larger surface fluctuation, and therefore, the scanning strategy is also avoided in the printing process.
3. And adopting a scanning strategy of deflecting each layer by random angles.
When the scanning strategy of deflecting random angles is adopted for each layer, the starting points among the layers are random, so that the quality randomness of the formed thin-wall cylinder is high, and the phenomenon of undulation still exists on the surface of the formed thin-wall cylinder as can be seen from figure 6.
4. A periodically varying scanning strategy is employed.
FIGS. 7 and 8 illustrate circular scanning strategies using cyclic scanning;
the scanning strategy used in fig. 7 has a first cycle start point of 0 degrees, spaced 60 degrees apart for each layer, a second cycle start point of 30 degrees, spaced 60 degrees apart for each layer, and then the two cycles are repeated;
the scanning strategy used in fig. 8 was to start with a first cycle at 0 degrees, 60 degrees apart for each layer, 30 degrees for a second cycle, 60 degrees apart for each layer, 0 degrees for a third cycle, 90 degrees apart for each layer, 45 degrees for a fourth cycle, 90 degrees apart for each layer, and then repeat the four cycles.
The adoption of the two scanning modes of periodically changing the scanning angle can effectively balance the uneven phenomenon at the beginning and the end of scanning and finally form a thin-wall cylinder with a smoother surface.
The depressed areas are automatically compensated.
Through the previous examples, it is found that the height of the initial position is higher than that of the end position when deposition is caused by the flow of the fluid in the molten pool, which is the main reason for the unevenness of the surface of the thin-wall cylinder, so that the height difference in the deposition process can be monitored in real time, the initial point of the next layer is located in the depression area, the depression is compensated, and finally a relatively flat thin-wall cylinder can be printed.
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-mentioned 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 modifications and embellishments within the scope of the invention may be made by those skilled in the art without departing from the principle of the invention.

Claims (6)

1. A thin-wall structure intelligent additive manufacturing accurate shape control method based on a dynamic compensation strategy is characterized by comprising the following steps:
The method comprises the following steps: establishing a fluid mechanics model of a thin-wall structure;
step two: establishing a control equation of a fluid mechanics model;
step three: printing the thin-wall structure of the same starting point of each layer according to the control equation in the second step;
step four: changing a scanning strategy according to the thin-wall structure shape obtained in the step three, and carrying out intelligent shape control on the thin-wall structure;
in the fourth step, when the height difference of the head and the tail of the thin-wall structure obtained in the third step is larger than a set threshold value, scanning strategies of 60-degree deflection and 180-degree deflection between adjacent layers are selected;
when the surface fluctuation of the thin-wall structure obtained in the step three is larger than a set threshold value, adopting a scanning strategy that adjacent layers respectively scan clockwise and anticlockwise;
when the thin-wall structure obtained in the step three has the phenomenon of fluctuation at a specific position, adopting a scanning strategy of deflecting each layer by random angles;
and when the unevenness at the beginning and the end of the thin-wall structure scanning obtained in the step three exceeds the set condition, adopting a scanning strategy which changes periodically.
2. The method for accurately controlling the shape of the thin-wall structure based on the dynamic compensation strategy in the intelligent additive manufacturing process is characterized in that the first step is specifically as follows: establishing a fluid mechanics model of a thin-wall structure, dividing grids, defining thermophysical properties of materials, and initializing the model.
3. The method for accurately controlling the shape of the thin-wall structure based on the intelligent additive manufacturing of the dynamic compensation strategy is characterized in that in the second step, the control equations comprise an energy conservation equation, a mass conservation equation, a momentum conservation equation and a phase equation;
conservation of mass equation:
Figure FDA0003696926280000011
conservation of momentum equation:
Figure FDA0003696926280000012
energy conservation equation:
Figure FDA0003696926280000013
phase equation:
Figure FDA0003696926280000014
where p is the density of the material,
Figure FDA0003696926280000015
is a velocity vector, t is time, S m Is a mass source term, p is pressure, mu is dynamic viscosity,
Figure FDA0003696926280000016
in order to be a momentum source term,
Figure FDA0003696926280000017
in order to be the marangoni force,
Figure FDA0003696926280000018
in order to be a surface tension force,
Figure FDA0003696926280000019
in order to be a buoyancy force,
Figure FDA00036969262800000110
damping force in the mushy zone, T is temperature, C p Is specific heat capacity, k is thermal conductivity, S T Is an energy source term, Q h Is surface heat, Q l Is the energy lost due to thermal convection, thermal radiation and evaporation.
4. The method for accurately controlling the shape of the thin-wall structure through intelligent additive manufacturing based on the dynamic compensation strategy is characterized in that in the second step, the heat source used by the model is a Gaussian heat source:
Figure FDA0003696926280000021
wherein f is a distribution factor, eta is an absorption rate, P is laser power, r is a laser radius, (x) 0 ,y 0 ) Is the laser beam center coordinate;
the initial temperature set was 298K, and the temperature boundary conditions were:
T(x,y,z,0)＝T 0 (x,y,z) (6)
The speed boundary condition is set to 0 at each boundary.
5. The method for the precise shape control of the intelligent additive manufacturing of the thin-wall structure based on the dynamic compensation strategy is characterized in that the scanning strategy which changes periodically is as follows:
the first cycle start point is 0 degrees, each layer is spaced by 60 degrees, the second cycle start point is 30 degrees, each layer is spaced by 60 degrees, and then the two cycles are repeated;
or the like, or, alternatively,
the first cycle start point is 0 degrees, each layer is spaced 60 degrees apart, the second cycle start point is 30 degrees, each layer is spaced 60 degrees apart, the third cycle start point is 0 degrees, each layer is spaced 90 degrees apart, the fourth cycle start point is 45 degrees, each layer is spaced 90 degrees apart, and then the four cycles are repeated.
6. The method for accurately controlling the shape of the thin-wall structure in the intelligent additive manufacturing process based on the dynamic compensation strategy of claim 1, wherein in the fourth step, the height difference in the deposition process in the third step is monitored in real time, so that the starting point of the next layer is located in the concave region, and the concave region is compensated, wherein the height difference refers to the difference between the maximum height and the minimum height of the top surface of the thin-wall structure from the surface of the substrate.
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