CN116484668A - Electron beam additive manufacturing process simulation method - Google Patents
Electron beam additive manufacturing process simulation method Download PDFInfo
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- CN116484668A CN116484668A CN202310334225.XA CN202310334225A CN116484668A CN 116484668 A CN116484668 A CN 116484668A CN 202310334225 A CN202310334225 A CN 202310334225A CN 116484668 A CN116484668 A CN 116484668A
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- 239000000654 additive Substances 0.000 title claims abstract description 119
- 230000000996 additive effect Effects 0.000 title claims abstract description 119
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 93
- 238000010894 electron beam technology Methods 0.000 title claims abstract description 53
- 238000000034 method Methods 0.000 title claims abstract description 53
- 238000004088 simulation Methods 0.000 title claims abstract description 36
- 230000004913 activation Effects 0.000 claims abstract description 16
- 238000004458 analytical method Methods 0.000 claims abstract description 8
- 239000000463 material Substances 0.000 claims description 17
- 238000009826 distribution Methods 0.000 claims description 7
- 230000003213 activating effect Effects 0.000 claims description 3
- 238000004364 calculation method Methods 0.000 abstract description 9
- 238000005457 optimization Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
Classifications
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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
- B22F10/80—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
- 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
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2111/00—Details relating to CAD techniques
- G06F2111/10—Numerical modelling
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2113/00—Details relating to the application field
- G06F2113/10—Additive manufacturing, e.g. 3D printing
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/08—Thermal analysis or thermal optimisation
-
- 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
Abstract
The invention discloses an electron beam additive manufacturing process simulation method, which creatively provides an additive manufacturing simulation calculation model for the process according to the requirements of electron beam additive manufacturing process characteristics and numerical simulation calculation, and provides an additive manufacturing unit activation flow and a heat source position positioning flow, so that the additive manufacturing simulation calculation model can be reasonably constructed and can be applied to the electron beam additive manufacturing process to realize the whole process numerical simulation of a cube additive manufacturing process. The invention realizes the calculation flow and high efficiency of the additive manufacturing process, can simulate the whole process of the electron beam additive manufacturing process, can help to improve the parameters of additive manufacturing, provides an effective simulation analysis means for the electron beam additive manufacturing process, and provides a new path for optimizing the process flow.
Description
Technical Field
The invention belongs to the technical field of electron beam additive manufacturing, and particularly relates to a design of an electron beam additive manufacturing process simulation method.
Background
Electron beam additive manufacturing is an additive manufacturing technique that uses a high-energy electron beam as a heat source to subject a material (typically metal powder) to a process of melting and solidifying, thereby achieving layer-by-layer stacking of the material. Compared with the traditional manufacturing mode, the electron beam additive manufacturing can quickly manufacture parts, greatly shortens the research and development period and reduces the manufacturing cost. At present, the process design and optimization mainly depends on experience and multiple test verification in China, and foreign countries are biased to basic research and process numerical simulation. With the great number of industrial applications of additive manufacturing processes, rapid assessment of the stress-strain distribution of the manufacturing process and adjustment of process parameters by numerical simulation has become an integral part of the additive process. The process simulation of electron beam additive manufacturing is an important guarantee for large-scale industrial application of the technology.
To achieve process simulation of electron beam additive, the overall process of additive manufacturing needs to be modeled. In the aspect of heat source, a large number of scholars and engineering personnel have been studied, and a relatively sufficient theoretical basis is provided. In modeling of a physical process of adding materials, no good simulation means are proposed at present, and more convenient material addition simulation is difficult to realize.
Disclosure of Invention
The invention aims to solve the problem that the conventional electron beam additive process simulation method is difficult to realize more convenient additive simulation, and provides an electron beam additive manufacturing process simulation method which can quickly complete the setting of additive manufacturing and the optimization of additive manufacturing process parameters.
The technical scheme of the invention is as follows: an electron beam additive manufacturing process simulation method comprises the following steps:
s1, determining the moving speed of a heat source based on an actual electron beam additive process, and constructing an electron beam additive manufacturing cube model.
S2, constructing an additive unit activation model according to the heat source moving speed and the electron beam additive manufacturing cubic model.
S3, constructing a heat source position model according to the heat source moving speed and the electron beam additive manufacturing cube model.
And S4, matching the additive unit activation model with the heat source position model.
S5, conducting heat conduction analysis on the matched active model of the additive unit and the heat source position model by adopting finite element software, and obtaining temperature field distribution in the additive manufacturing process.
S6, analyzing the temperature field distribution, modifying parameters of the heat source position model according to an analysis result, perfecting the heat source position model, realizing simulation of the electron beam additive manufacturing process, and improving the process flow of the electron beam additive manufacturing according to a simulation result.
Further, building the electron beam additive manufacturing cube model in step S1 includes determining a length L, a width W, a height H, and a cell size L of the cube model element And the length L is along the x-axis direction, the width W is along the z-axis direction, and the height H is along the y-axis direction.
Further, step S2 includes the following sub-steps:
s21, building an additive unit activation sequence according to the heat source moving speed and the electron beam additive manufacturing cube model:
wherein n is l 、n w 、n h The number of units in the length, width and height directions of the cube model are respectively represented, t d Representing the time required for the additive to complete a cell, V hs Indicating the heat source movement speed.
S22, initializing the setup time t=0, the additive manufacturing layer row=0, and the y-axis direction parameter y=0.5l element 。
S23, judging whether Row is less than n h If yes, go to step S24, otherwise go to step S3.
S24, setting the additive manufacturing cell number column=0, and x-axis direction parameter x=0.5l element 。
S25, judging whether Columbus < n is satisfied l If yes, go to step S26, otherwise, increase the additive manufacturing layer number Row by 1 and increase the y-axis direction parameter y by one unit cell size L element The process returns to step S23.
S26, setting the additive manufacturing column number line=0, and the z-axis direction parameter z=0.5l element 。
S27, judging whether Line < n is satisfied w If yes, go to step S28, otherwise, increase the additive manufacturing cell number Column plus 1, the x-axis direction parameter x by one cell size L element The process returns to step S25.
S28, activating the unit cell with the coordinates of (x, y, z) at the time t, and increasing the additive manufacturing column number Line by 1 and the z-axis direction parameter z by one unit cell size L element Time t is increased by t d The process returns to step S27.
Further, step S3 includes the following sub-steps:
s31, calculating time t required for completing a list of additive manufacturing according to the heat source moving speed and the electron beam additive manufacturing cube model line And the time t for completing one layer of additive row ：
t row ＝t line n l
S32, acquiring the current time t and the initial position (x) 0 ,y 0 ,z 0 )。
S33, calculating and obtaining a total heat source moving distance d according to the current time t:
d＝V hs ×t
s34, calculating according to the current time t to obtain the total number of columns i of the material addition completion, the number of columns j of the current layer in the material addition process and the number of layers k in the material addition process:
j＝mod(i,n l )
where floor (-) represents a round down function and mod (-) represents a remainder function.
S35, calculating to obtain the current heat source position (x hs ,y hs ,z hs )：
x hs ＝j×L element +x 0
y hs ＝k×L element +y 0
z hs ＝-i×n w ×L element +d+z 0
The beneficial effects of the invention are as follows:
(1) Aiming at the requirements of electron beam additive manufacturing process characteristics and numerical simulation calculation, the invention creatively provides an additive manufacturing simulation calculation model aiming at the process, and provides an additive manufacturing unit activation flow and a heat source position positioning flow, so that the additive manufacturing simulation calculation model can be reasonably constructed and can be applied to the electron beam additive manufacturing process, and the whole process numerical simulation of a cube additive manufacturing process is realized.
(2) The invention can quickly complete the establishment of the model through the constructed additive manufacturing simulation calculation flow, not only can improve the simulation calculation efficiency, but also has the advantage of flow, can provide an effective simulation analysis means for the electron beam additive manufacturing process, and provides a new path for process flow optimization.
Drawings
Fig. 1 is a flow chart of a simulation method of an electron beam additive manufacturing process according to an embodiment of the present invention.
Fig. 2 is a schematic diagram of an electron beam additive manufacturing cubic model according to an embodiment of the present invention.
Detailed Description
Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It is to be understood that the embodiments shown and described in the drawings are merely illustrative of the principles and spirit of the invention and are not intended to limit the scope of the invention.
The embodiment of the invention provides a simulation method of an electron beam additive manufacturing process, which is shown in fig. 1 and comprises the following steps S1 to S6:
s1, determining the moving speed of a heat source based on an actual electron beam additive process, and constructing an electron beam additive manufacturing cube model.
In the embodiment of the invention, the built electron beam additive manufacturing cube model is shown in fig. 2, and the length L, the width W, the height H and the cell size L of the cube model need to be determined element And the length L is along the x-axis direction, the width W is along the z-axis direction, and the height H is along the y-axis direction.
S2, constructing an additive unit activation model according to the heat source moving speed and the electron beam additive manufacturing cubic model.
Step S2 includes the following substeps S21 to S28:
s21, building an additive unit activation sequence according to the heat source moving speed and the electron beam additive manufacturing cube model:
wherein n is l 、n w 、n h The number of units in the length, width and height directions of the cube model are respectively represented, t d Representing the time required for the additive to complete a cell, V hs Indicating the heat source movement speed.
S22, initializing the setup time t=0, the additive manufacturing layer row=0, and the y-axis direction parameter y=0.5l element 。
S23, judging whether Row is less than n h If yes, go to step S24, otherwise go to step S3.
S24, setting the additive manufacturing cell number column=0, and x-axis direction parameter x=0.5l element 。
S25, judging whether Columbus < n is satisfied l If so, the process proceeds to step S26,if not, increasing the additive manufacturing layer number Row by 1 and increasing the y-axis direction parameter y by one unit cell size L element The process returns to step S23.
S26, setting the additive manufacturing column number line=0, and the z-axis direction parameter z=0.5l element 。
S27, judging whether Line < n is satisfied w If yes, go to step S28, otherwise, increase the additive manufacturing cell number Column plus 1, the x-axis direction parameter x by one cell size L element The process returns to step S25.
S28, activating the unit cell with the coordinates of (x, y, z) at the time t, and increasing the additive manufacturing column number Line by 1 and the z-axis direction parameter z by one unit cell size L element Time t is increased by t d The process returns to step S27.
In the embodiment of the invention, the heat source is assumed to start from the original point and finish a process with length W and width L along the direction of width W (z axis) element Is added, then the x-axis is moved forward by one cell size L element And completing a row of additive materials along the positive direction of the z axis. The above process is repeated until one layer of additive manufacturing is completed. The heat source will move forward one cell size L along the y-axis for the next layer of additive material element The motion of the previous layer is repeated multiple times until the additive manufacturing of the entire cubic model is completed.
S3, constructing a heat source position model according to the heat source moving speed and the electron beam additive manufacturing cube model.
Step S3 includes the following substeps S31 to S35:
s31, calculating time t required for completing a list of additive manufacturing according to the heat source moving speed and the electron beam additive manufacturing cube model line And the time t for completing one layer of additive row ：
t row ＝t line n l
S32, acquiring the current time t and the initial position (x) 0 ,y 0 ,z 0 )。
S33, calculating and obtaining a total heat source moving distance d according to the current time t:
d＝V hs ×t
s34, calculating according to the current time t to obtain the total number of columns i of the material addition completion, the number of columns j of the current layer in the material addition process and the number of layers k in the material addition process:
j＝mod(i,n l )
where floor (-) represents a round down function and mod (-) represents a remainder function.
S35, calculating to obtain the current heat source position (x hs ,y hs ,z hs )：
x hs ＝j×L element +x 0
y hs ＝k×L element +y 0
z hs ＝-i×n w ×L element +d+z 0
In the embodiment of the invention, the column number j of the current layer is multiplied by the cell size L element I.e. the distance the heat source moves in the x-direction of the current layer, the number of layers k of the current layer multiplied by the cell size L element That is, the distance that the heat source moves in the y direction of the current layer, the total number i of additive completed columns multiplied by the distance (width W) of one column of additive is the total length of the completed columns, and the difference between the total distance d that the heat source moves and the value is exactly the distance that the heat source moves in the z axis in the column of the current additive.
And S4, matching the additive unit activation model with the heat source position model.
In the embodiment of the invention, when the additive unit activation model is constructed, the heat source moving speed V in the heat source position model is used hs WhileRelated parameters in the additive unit activation model are also needed to be used in constructing the heat source position model, so that the matching of heat source movement and unit activation can be realized through unification of related basic parameters in the two models and adjustment of the unit activation direction and the heat source movement direction.
S5, conducting heat conduction analysis on the matched active model of the additive unit and the heat source position model by adopting finite element software, and obtaining temperature field distribution in the additive manufacturing process.
S6, analyzing the temperature field distribution, modifying parameters of the heat source position model according to an analysis result, perfecting the heat source position model, realizing simulation of the electron beam additive manufacturing process, and improving the process flow of the electron beam additive manufacturing according to a simulation result.
Those of ordinary skill in the art will recognize that the embodiments described herein are for the purpose of aiding the reader in understanding the principles of the present invention and should be understood that the scope of the invention is not limited to such specific statements and embodiments. Those of ordinary skill in the art can make various other specific modifications and combinations from the teachings of the present disclosure without departing from the spirit thereof, and such modifications and combinations remain within the scope of the present disclosure.
Claims (4)
1. The electron beam additive manufacturing process simulation method is characterized by comprising the following steps of:
s1, determining a heat source moving speed based on an actual electron beam material adding process, and constructing an electron beam material adding manufacturing cube model;
s2, constructing an additive unit activation model according to the heat source moving speed and the electron beam additive manufacturing cubic model;
s3, constructing a heat source position model according to the heat source moving speed and the electron beam additive manufacturing cube model;
s4, matching the additive unit activation model with the heat source position model;
s5, performing heat conduction analysis on the matched additive unit activation model and the heat source position model by adopting finite element software to obtain temperature field distribution in the additive manufacturing process;
s6, analyzing the temperature field distribution, modifying parameters of the heat source position model according to an analysis result, perfecting the heat source position model, realizing simulation of the electron beam additive manufacturing process, and improving the process flow of the electron beam additive manufacturing according to a simulation result.
2. The method according to claim 1, wherein constructing the electron beam additive manufacturing cubic model in step S1 includes determining a length L, a width W, a height H, and a cell size L of the cubic model element And the length L is along the x-axis direction, the width W is along the z-axis direction, and the height H is along the y-axis direction.
3. The electron beam additive manufacturing process simulation method according to claim 2, wherein the step S2 comprises the following sub-steps:
s21, building an additive unit activation sequence according to the heat source moving speed and the electron beam additive manufacturing cube model:
wherein n is l 、n w 、n h The number of units in the length, width and height directions of the cube model are respectively represented, t d Representing the time required for the additive to complete a cell, V hs Indicating the heat source movement speed;
s22, initializing the setup time t=0, the additive manufacturing layer row=0, and the y-axis direction parameter y=0.5l element ；
S23, judging whether Row is less than n h If yes, enter step S24, otherwise enter step S3;
s24, setting the additive manufacturing cell number column=0, and x-axis direction parameter x=0.5l element ；
S25, judging whether Columbus < n is satisfied l If yes, go to step S26, otherwise, add 1, y-axis direction parameter to the additive manufacturing layer number RowThe number y is increased by one cell size L element Returning to step S23;
s26, setting the additive manufacturing column number line=0, and the z-axis direction parameter z=0.5l element ；
S27, judging whether Line < n is satisfied w If yes, go to step S28, otherwise, increase the additive manufacturing cell number Column plus 1, the x-axis direction parameter x by one cell size L element Returning to step S25;
s28, activating the unit cell with the coordinates of (x, y, z) at the time t, and increasing the additive manufacturing column number Line by 1 and the z-axis direction parameter z by one unit cell size L element Time t is increased by t d The process returns to step S27.
4. A method of simulating an electron beam additive manufacturing process according to claim 3, wherein step S3 comprises the sub-steps of:
s31, calculating time t required for completing a list of additive manufacturing according to the heat source moving speed and the electron beam additive manufacturing cube model line And the time t for completing one layer of additive row ：
t row ＝t line n l
S32, acquiring the current time t and the initial position (x) 0 ,y 0 ,z 0 )；
S33, calculating and obtaining a total heat source moving distance d according to the current time t:
d＝V hs ×t
s34, calculating according to the current time t to obtain the total number of columns i of the material addition completion, the number of columns j of the current layer in the material addition process and the number of layers k in the material addition process:
j＝mod(i,n l )
wherein floor (·) represents a downward rounding function, mod (·) represents a remainder function;
s35, calculating to obtain the current heat source position (x hs ,y hs ,z hs )：
x hs ＝j×L element +x 0
y hs ＝k×L element +y 0
z hs ＝-i×n w ×L element +d+z 0 。
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116702631A (en) * | 2023-08-08 | 2023-09-05 | 四川大学 | Electron beam additive manufacturing constitutive relation calculation method based on artificial neural network |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116702631A (en) * | 2023-08-08 | 2023-09-05 | 四川大学 | Electron beam additive manufacturing constitutive relation calculation method based on artificial neural network |
| CN116702631B (en) * | 2023-08-08 | 2023-10-27 | 四川大学 | Electron beam additive manufacturing constitutive relation calculation method based on artificial neural network |
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