CN116060641A - Nickel-based superalloy selective laser melting forming simulation and structure optimization method - Google Patents
Nickel-based superalloy selective laser melting forming simulation and structure optimization method Download PDFInfo
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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
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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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]
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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
- B22F10/30—Process control
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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Abstract
The invention discloses a method for simulating and optimizing a nickel-based superalloy selective laser melting forming and structure; the method comprises the following steps: establishing a three-dimensional model of the part in 3D modeling software, and exporting the model into an STL file; adding support to the model in the additive manufacturing software; importing a model into simulation software and setting related parameters to start running the simulation software; solving to obtain displacement deformation and stress distribution of the part in the laser additive manufacturing process; analyzing the solving result, and carrying out structural optimization design on the parts to avoid forming failure; according to the invention, the simulation software is adopted to simulate the displacement deformation and stress distribution of the GH3536 nickel-based superalloy part manufactured by laser additive, so that technical guidance is provided for smooth forming of aerospace high-performance parts by laser additive manufacturing, and the reduction of trial-and-error cost and the improvement of forming quality are facilitated.
Description
Technical Field
The invention relates to the field of metal additive manufacturing, in particular to a method for simulating selective laser melting forming and optimizing a structure of a nickel-based superalloy.
Background
The nickel-based superalloy not only has higher high-temperature strength and oxidation resistance, but also has excellent fatigue resistance, so that the nickel-based superalloy has a significant position in the whole superalloy field and is widely applied to the aerospace industry. GH3536 is a typical solid solution strengthening nickel-based superalloy, which has good high-temperature durability at temperatures below 900 ℃, and thus is applied to the preparation of aeroengine combustors and other parts that are in service at high temperatures. In recent years, competition among the large countries for the aerospace field is more and more intense, and requirements for light-weight and high-strength structures are more and more high, so that great pressure is exerted on the traditional manufacturing industry.
The selective laser melting is used as an advanced near-net forming technology, and can solve the problem that the traditional processing method is difficult to manufacture parts with complex structures and ultrafine grain structures. Therefore, selective laser melting is considered to be the optimal solution for manufacturing nickel-base superalloy components. However, because the selective laser melting technology has high temperature gradient and rapid solidification, the material has metallurgical defects such as cracks, pores and the like in the forming process, which significantly affects the mechanical properties of the part. And due to the principle and the technological process of the selective laser melting technology, the cracking and deformation can greatly influence the printing effect of the next layer of powder, and the failure of the forming process can be directly caused.
The method for forming the nickel-based superalloy by selective laser melting is disclosed in publication No. CN109439962A, and adopts a powder bed selective laser melting forming process to prepare a nickel-based superalloy forming piece with high density, good internal quality, few defects and excellent mechanical property; however, the method adopts the selective laser melting technology, and the nickel-based superalloy material has metallurgical defects such as cracks, pores and the like in the forming process, which obviously affects the mechanical properties of parts.
Therefore, the invention provides a method for simulating selective laser melting forming and optimizing the structure of the nickel-based superalloy, which is used for reducing trial-and-error cost and improving forming quality of complex parts.
Disclosure of Invention
The invention aims to provide a method for simulating selective laser melting forming and optimizing a structure of a nickel-based superalloy, which can simulate stress and displacement deformation of a part in a laser additive manufacturing process, and can optimally design a part model according to the result so as to improve the suitability of the part and an additive manufacturing technology, effectively reduce trial-and-error cost and improve part forming quality.
The invention adopts the following specific technical scheme:
the method for simulating and optimizing the structure of the selective laser melting forming of the nickel-based superalloy is characterized by comprising the following steps of:
s1: establishing a part model by adopting three-dimensional modeling software according to a CAD drawing, and exporting the model into an STL format;
s2: generating a support of a model of the part by using additive manufacturing software, and manually modifying the support type and the support density according to the characteristics of the part;
s3: adopting simulation software to divide voxels of the part and the supported model;
s4: setting support types and parameters, material configuration and required output result types in simulation software, and starting to run the simulation software;
s5: and (4) obtaining the forming stress distribution and displacement deformation result of the nickel-based superalloy manufactured by laser additive by adopting simulation software on the basis of the step (S4).
Further, in the step S1, the tolerance of the part model is set to 0.001 mm during the format conversion, and there is inevitably a certain deviation during the format conversion, the deviation is the maximum distance between the originally established curved surface or entity and the mesh required to establish the STL format, and in order to ensure that the part is not distorted during the format conversion, care is taken to set the tolerance to 0.001 mm.
Further, the nickel-based superalloy model in S1 requires checking the sealing of the model after the establishment is completed.
Further, the inspection model adopts an edge detection tool to check the model closure, and if the model passes, the model is free of an edge leakage; if an edge is shown to leak, it is necessary to check if the surface or mesh around the edge is joined intact.
Further, the support type in the step S2 includes a contour support and a sheet support.
Further, the support density is a support interval of 1 to 2 mm.
Further, the voxels in step S3 are square blocks having a smaller side length, and the side length of the square block is set to 0.25 to 0.5 mm.
Further, the part model is composed of a plurality of voxels.
Further, IN the material configuration of step S4, the option of temporarily eliminating the nickel-based alloy GH3536 is selected, and the IN625 alloy with relatively similar performance is selected to replace the simulation.
The structural optimization method comprises the steps of carrying out structural optimization redesign on dangerous areas generated by parts according to the forming stress distribution and displacement deformation results of the nickel-based superalloy manufactured by laser additive obtained by the simulation method; the structural optimization method has the specific contents that the supporting density is added or increased in the larger area of the part hanging surface, in addition, the part placing angle is set to be 45 degrees, the supporting of the inside of the part is reduced as much as possible, the principle that the maximum hanging angle is 45 degrees is fully utilized, and the roughness of the surface of the part is ensured to the greatest extent.
The beneficial effects of the invention are as follows:
(1) According to the invention, the stress level and deformation displacement conditions of the part in the forming process are analyzed by utilizing simulation solution, the structural optimization design is carried out on the model and the support according to the solving result, the defects generated in the forming process of the part are reduced, the printing success rate of the part is improved, and a foundation is laid for the additive manufacturing process of the complex part.
(2) The invention can improve the successful forming rate of complex parts and reduce the risk cost and the time cost to a certain extent. The structure optimization design can assist industrial production, and plays a role in promoting large-scale commercial application of simulation software in the field of additive manufacturing.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required to be used in the embodiments or the description of the prior art will be briefly described below, and it is obvious that the drawings in the following description are only embodiments of the present invention, and that other drawings can be obtained according to the provided drawings without inventive effort for a person skilled in the art.
Fig. 1 (a) shows a displacement variation of an embodiment of the present invention, and fig. 1 (b) shows a stress distribution of an embodiment of the present invention.
Fig. 2 (a) shows the displacement deformation of comparative example 1 of the present invention, and fig. 2 (b) shows the stress distribution of comparative example 2 of the present invention.
Fig. 3 (a) shows the displacement deformation of comparative example 2 of the present invention, and fig. 3 (b) shows the stress distribution of comparative example 3 of the present invention.
Fig. 4 (a) shows the displacement deformation of comparative example 3 of the present invention, and fig. 4 (b) shows the stress distribution of comparative example 3 of the present invention.
Detailed Description
In order that the above-recited objects, features and advantages of the present invention will become more apparent, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, but the present invention may be practiced in other ways other than those described herein, and persons skilled in the art will readily appreciate that the present invention is not limited to the specific embodiments disclosed below. Further, reference herein to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic can be included in at least one implementation of the invention. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments.
Example 1
A simulation method for selective laser melting forming of nickel-based superalloy comprises the following steps:
s1: establishing a part model in three-dimensional modeling software Rhino according to a CAD drawing, verifying the closure of the model after the model is established, and exporting the model into an STL format; the inspection model adopts an edge detection tool to check the model closure, and if the model passes, the model is free of an edge leakage; if the leakage edge is displayed, checking whether the curved surface or the grid near the edge is completely jointed or not; in the format conversion, in order to ensure that the part is not distorted in the format conversion process, the tolerance is set to be 0.001 millimeter;
s2: the method comprises the steps of importing a model of a part into additive manufacturing professional software Magics to generate a support, and manually modifying the support type and the support density according to part characteristics, wherein the support type comprises a contour support and a sheet support, and the set support density is about 2 mm;
s3: the method comprises the steps of importing a part and a supported model into simulation software ANSYS Additive, dividing voxels, and setting the side length of the voxels to be 0.32 mm according to the memory required by calculation;
s4: setting the support type as manual input, and selecting materials to be configured as IN625 alloy due to the lack of GH3536 nickel-based superalloy data IN simulation software, wherein the minimum tensile strength of the IN625 alloy at normal temperature is 760MPa, and the GH3536 nickel-based superalloy manufactured by laser additive has the strength of more than 750MPa, and the room temperature performances of the two alloys are similar; setting the result to be output as displacement deformation and stress distribution, and starting to run simulation software;
s5: and (4) obtaining the forming stress distribution and displacement deformation result of the nickel-based superalloy manufactured by laser additive by adopting simulation software on the basis of the step (S4).
The structural optimization method carries out structural optimization redesign on dangerous areas generated by parts according to the stress distribution and displacement deformation results of the nickel-based superalloy forming manufactured by laser additive material obtained by the simulation method; the structural optimization method specifically comprises the steps of adding or increasing the supporting density in a larger area of a part hanging surface, setting the part placement angle to be 45 degrees, reducing the support in the part as far as possible, fully utilizing the principle that the maximum hanging angle is 45 degrees, ensuring the roughness of the surface of the part to the greatest extent, guiding the structural optimization content into the simulation method to operate, and obtaining a displacement deformation map and a stress distribution map of a part model, as shown in fig. 1 (a) and 1 (b), wherein fig. 1 (a) and 1 (b) are the displacement deformation map and the stress distribution map of the part model respectively.
The invention has the beneficial effects that: according to the invention, the stress level and deformation displacement conditions of the part in the forming process are analyzed by utilizing simulation solution, the structural optimization design is carried out on the model and the support according to the solving result, the defects generated in the forming process of the part are reduced, the printing success rate of the part is improved, and a foundation is laid for the additive manufacturing process of the complex part.
The invention can improve the successful forming rate of complex parts and reduce the risk cost and the time cost to a certain extent. The structure optimization design can assist industrial production, and plays a role in promoting large-scale commercial application of simulation software in the field of additive manufacturing.
Comparative example 1
Comparative example 1 provides a simulation method for selective laser melting forming of a nickel-based superalloy, which comprises the following steps:
s1: establishing a part model in three-dimensional modeling software Rhino according to a CAD drawing, verifying the closure of the model after the model is established, and exporting the model into an STL format; the inspection model adopts an edge detection tool to check the model closure, and if the model passes, the model is free of an edge leakage; if the leakage edge is displayed, checking whether the curved surface or the grid near the edge is completely jointed or not; in the format conversion, in order to ensure that the part is not distorted in the format conversion process, the tolerance is set to be 0.001 millimeter;
s2: in order to investigate the change of the unsupported complex part after forming, a model of the part is imported into additive manufacturing professional software Magics to directly slice, and no support is generated;
s3: the method comprises the steps of importing a part and a supported model into simulation software ANSYS Additive, dividing voxels, and setting the side length of the voxels to be 0.32 mm according to the memory required by calculation;
s4: setting the support type as manual input, and selecting materials to be configured as IN625 alloy with similar room temperature performance due to the lack of GH3536 nickel-based superalloy data IN simulation software; the angle of the part model is not processed, the result required to be output is set as displacement deformation and stress distribution, and simulation software starts to run;
s5: and (3) obtaining the forming stress distribution and displacement deformation results of the nickel-based superalloy manufactured by laser additive on the basis of the step S4 by adopting simulation software, wherein the obtained displacement deformation diagram of the part model is a stress distribution diagram, as shown in fig. 2 (a) and 2 (b), and the fig. 2 (a) and 2 (b) are respectively the displacement deformation diagram and the stress distribution diagram of the part model of the comparative example 1.
Comparative example 2
Comparative example 2 provides a simulation method for selective laser melting forming of a nickel-based superalloy, which comprises the following steps:
s1: establishing a part model in three-dimensional modeling software Rhino according to a CAD drawing, verifying the closure of the model after the model is established, and exporting the model into an STL format; the inspection model adopts an edge detection tool to check the model closure, and if the model passes, the model is free of an edge leakage; if the leakage edge is displayed, checking whether the curved surface or the grid near the edge is completely jointed or not; in the format conversion, in order to ensure that the part is not distorted in the format conversion process, the tolerance is set to be 0.001 millimeter;
s2: the method comprises the steps of importing a model of a part into additive manufacturing professional software Magics to generate a support, and manually modifying the support type and the support density according to part characteristics, wherein the support type comprises a contour support and a sheet support, and the set support density is about 2 mm;
s3: the method comprises the steps of importing a part and a supported model into simulation software ANSYS Additive, dividing voxels, and setting the side length of the voxels to be 0.32 mm according to the memory required by calculation;
s4: setting the support type as manual input, and selecting materials to be configured as IN625 alloy with similar room temperature performance due to the lack of GH3536 nickel-based superalloy data IN simulation software; the angle of the part model is not processed, the result required to be output is set as displacement deformation and stress distribution, and simulation software starts to run;
s5: and (3) obtaining the forming stress distribution and the displacement deformation result of the nickel-based superalloy manufactured by laser additive on the basis of the step (S4), wherein the obtained displacement deformation diagram of the part model is a stress distribution diagram, as shown in fig. 3 (a) and 3 (b), and the fig. 3 (a) and 3 (b) are respectively the displacement deformation diagram and the stress distribution diagram of the part model of the comparative example 2.
Comparative example 3
Comparative example 3 provides a simulation method for selective laser melting forming of a nickel-based superalloy, which comprises the following steps:
s1: establishing a part model in three-dimensional modeling software Rhino according to a CAD drawing, verifying the closure of the model after the model is established, and exporting the model into an STL format; the inspection model adopts an edge detection tool to check the model closure, and if the model passes, the model is free of an edge leakage; if the leakage edge is displayed, checking whether the curved surface or the grid near the edge is completely jointed or not; in the format conversion, in order to ensure that the part is not distorted in the format conversion process, the tolerance is set to be 0.001 millimeter;
s2: the model of the part is imported into additive manufacturing professional software Magics to be directly sliced, and no support is generated;
s3: the method comprises the steps of importing a part and a supported model into simulation software ANSYS Additive, dividing voxels, and setting the side length of the voxels to be 0.32 mm according to the memory required by calculation;
s4: setting the support type as manual input, and selecting materials to be configured as IN625 alloy with similar room temperature performance due to the lack of GH3536 nickel-based superalloy data IN simulation software; the angle of the part model is not processed, the result required to be output is set to be displacement deformation and stress distribution, the angle of the part is set to be 45 degrees, and simulation software starts to run;
s5: and (3) obtaining the forming stress distribution and the displacement deformation result of the nickel-based superalloy manufactured by laser additive on the basis of the step (S4), wherein the obtained displacement deformation diagram of the part model is a stress distribution diagram, as shown in fig. 4 (a) and 4 (b), and the obtained displacement deformation diagram of the part model of the comparative example 3 are respectively a displacement deformation diagram and a stress distribution diagram of the part model of the comparative example 4 (a) and 4 (b).
By comparing the comparative example 1 with the comparative example 2, it was found that the maximum deformation amount of the part after the addition of the support was reduced by one order of magnitude as compared with the unsupported direct formed part, and the simulation result of the unsupported part showed that the maximum displacement deformation of the part was 1mm or more, which obviously caused a serious decrease in the functionality of the part.
By comparing comparative example 1 with comparative example 3, it was found that the area where severe deformation occurs when the parts are placed at 45 ° was reduced, since the parts themselves use a self-supporting structure when the overhang angle is 45 °, and thus the formation can be smoothly performed without additional support at the structure where the overhang angle is 45 °. This indicates that the amount of support and the support density that needs to be added can be reduced by a suitable amount.
According to the comparison example 1 and the comparison example 1, the displacement deformation of the parts is effectively controlled after the supports are added to the parts and are placed at 45 degrees, and the parts can be effectively fixed by only increasing the number of the supports in a dangerous area to improve the support density, so that the parts are prevented from deforming and collapsing downwards.
According to the invention, through simulating the displacement deformation and stress distribution of the GH3536 nickel-based superalloy part manufactured by laser additive, necessary structural dimension optimization is performed on the part according to a solving result so as to adapt to additive manufacturing industrial production, technical guidance is provided for smooth forming of aerospace high-performance parts by laser additive manufacturing, and the reduction of trial and error cost and the improvement of forming quality are facilitated.
It is to be understood that the above examples of the present invention are provided by way of illustration only and not by way of limitation of the embodiments of the present invention. Other variations or modifications of the above teachings will be apparent to those of ordinary skill in the art. It is not necessary here nor is it exhaustive of all embodiments. Any modification, equivalent replacement, improvement, etc. which come within the spirit and principles of the invention are desired to be protected by the following claims.
Claims (10)
1. The simulation method for selective laser melting forming of the nickel-based superalloy is characterized by comprising the following steps of:
s1: establishing a part model by adopting three-dimensional modeling software according to a CAD drawing, and exporting the model into an STL format;
s2: generating a support of a model of the part by using additive manufacturing software, and manually modifying the support type and the support density according to the characteristics of the part;
s3: adopting simulation software to divide voxels of the part and the supported model;
s4: setting support types and parameters, material configuration and required output result types in simulation software, and starting to run the simulation software;
s5: and (4) obtaining the forming stress distribution and displacement deformation result of the nickel-based superalloy manufactured by laser additive by adopting simulation software on the basis of the step (S4).
2. The simulation method for selective laser melting forming of nickel-base superalloy according to claim 1, wherein the tolerance of the part model in step S1 is set to 0.001 mm during format conversion.
3. The simulation method for selective laser melting forming of nickel-base superalloy according to claim 1, wherein the nickel-base superalloy model in S1 is required to check the sealing property of the model after the establishment is completed.
4. The simulation method for selective laser melting forming of nickel-base superalloy according to claim 1, wherein the inspection model uses an edge detection tool to inspect model closure.
5. The simulation method for selective laser melting forming of nickel-base superalloy according to claim 1, wherein the support type in step S2 includes a contour support and a sheet support.
6. The simulation method for selective laser melting forming of nickel-base superalloy according to claim 1, wherein the support density is 1 to 2 mm support spacing.
7. The method of simulation and structural optimization of selective laser melting forming of nickel-base superalloy according to claim 1, wherein the voxels in step S3 are square blocks with smaller side lengths, and the side lengths of the square blocks are set to 0.25 to 0.5 mm.
8. The simulation method for selective laser melting forming of nickel-base superalloy according to claim 1, wherein the part model is composed of a plurality of voxels.
9. The simulation method for selective laser melting forming of nickel-base superalloy according to claim 1, wherein the material configuration IN step S4 is selected so as to temporarily eliminate the option of nickel-base alloy GH3536, and an IN625 alloy with relatively similar performance is selected for simulation.
10. The method for optimizing the nickel-based superalloy selective laser melting forming structure is characterized in that the structural optimization redesign is carried out on dangerous areas generated by parts according to the forming stress distribution and displacement deformation results of the nickel-based superalloy manufactured by laser additive materials obtained by the simulation method of claims 1-9;
the method for optimizing the structure comprises the steps of adding or increasing the supporting density in a region with a larger overhanging surface of the part, and setting the placing angle of the part to be 45 degrees.
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CN116921700B (en) * | 2023-09-15 | 2023-12-08 | 四川工程职业技术学院 | Laser selective melting forming anti-deformation method for high-temperature alloy |
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