CN116663189A - Design method of porous structure for additive manufacturing and metal guard plate - Google Patents
Design method of porous structure for additive manufacturing and metal guard plate Download PDFInfo
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Abstract
The invention belongs to the field of computer aided design, and particularly relates to a design method of a porous structure for additive manufacturing and a metal guard plate. According to the invention, by combining the characteristics of the additive manufacturing process, through computer simulation and real-part test experimental means, the performance requirements in the actual application scene are comprehensively considered, and analysis is performed from the angles of mechanical properties and thermal management properties, so that a method capable of designing a porous structure with composite properties is obtained, experimental parameters of the design method are optimized, and the rationality and accuracy of the design method and the compatibility of different equipment, processes, materials and products are improved. The design method also obtains the conclusion that the TPMS sheet-shaped structure Schoen-Gyroid and Schwarz-Diamond have excellent weight reduction, energy absorption, vibration isolation and thermal management composite performance, and provides guidance significance for the application of the porous structure in the field of additive manufacturing in the aerospace field.
Description
Technical Field
The invention belongs to the field of computer aided design, in particular to the field of classification number G06F30/00, and more particularly relates to a design method of an additive manufacturing porous structure and a guard plate.
Background
The traditional part processing is usually a material reduction manufacturing method, namely, the workpiece material is processed by physical (electric, acoustic, optical, thermal, magnetic), chemical or electrochemical methods such as turning, milling, planing, grinding, tooth surface processing, complex curved surface processing of a numerical control machine tool and the like, but the method has large material consumption, and the processing of each part can be completed through a plurality of working procedures by using a plurality of cutters and clamps.
Additive manufacturing (Additive Manufacturing, AM), 3D printing, is a special machining technique for constructing parts by layer-by-layer printing using metallic or non-metallic materials based on three-dimensional digital models. As a rapid and accurate part processing method, the method is applied to the fields of aerospace, automobiles, medical treatment, dies, buildings and the like.
Porous materials (cellular solids), which are three-dimensional structures formed by aggregation of a large number of polyhedral or spherical void spaces, have dual properties of functions and structures, and can be used in a variety of fields such as separation, filtration, catalyst support, thermal management, sound attenuation, vibration absorption, weight reduction, buffering, medical treatment, etc. With the expansion of application fields and the improvement of use demands, the structure of the required porous material is more and more complex, the complex porous structure is difficult to be processed by a material reduction manufacturing process, and the qualification rate of products is lower. The appearance and development of the additive manufacturing technology enable the processing of extremely complex porous structures to be possible, the energizing of the additive manufacturing technology is achieved, and the porous materials can achieve higher added value in the precise fields of aerospace, nuclear power, medical treatment, high-end tools and the like.
In order to adapt to the requirements of different application scenes, the structure of the porous material needs to be designed. Researchers at home and abroad continuously optimize the design method of the porous structure. The prior art CN 112036063B discloses a design modeling method of a TPMS structure for additive manufacturing, which provides a new idea of lightweight design. However, there is no systematic method for optimizing parameters such as unit cell type and size to adapt to different processing conditions and application scenarios.
Disclosure of Invention
In view of the drawbacks of the prior art, an object of the present invention is to provide a design method for additive manufacturing of porous structures.
On the other hand, the invention also aims to provide a metal guard plate designed by the design method for manufacturing the porous structure through the additive.
In order to achieve the aim of the invention, the invention adopts the following technical scheme:
a design method for additive manufacturing porous structures, comprising the steps of:
s1: fixing additive manufacturing equipment, materials and process parameters, and selecting unit cell types of a porous structure for modeling;
s2: determining the unit cell size range of the porous structure;
s3: determining the relative density range of the porous structure;
s4: screening the single cell type of the porous structure;
s5: designing a round angle for connecting the porous structure with the shell;
s6: static mechanical analysis of the porous structure;
s7: and analyzing the heat management performance of the porous structure.
Preferably, the fixing the additive manufacturing device, the materials and the process parameters in the step S1 includes: fixing an additive manufacturing device, fixing a set of laser process parameters, fixing a printing layer thickness, fixing a scraper system, fixing materials and fixing powder sieving and mixing specifications.
Preferably, the additive manufacturing apparatus is a laser forming apparatus having a spot of less than 100 μm;
preferably, the laser process parameters adopt a mode of combining contour bias with single-path scanning;
preferably, the thickness of the printing layer is 20-40 μm;
preferably, the doctor blade system is a flexible doctor blade system.
The material is not particularly limited and may be selected from all materials that can be used for additive manufacturing; examples include copper alloys, aluminum alloys, titanium alloys, stainless steel, superalloys, nonmetallic materials, and the like.
Various variable factors in the 3D printing forming cabin influence the performance and quality of manufactured parts, and even parts processed by the same equipment with the same parameters in different areas have different performances, so that the equipment and the parameters need to be fixed before the design is performed. The large spot diameter is not beneficial to forming a porous structure with thin-wall details, and in the design method of the invention, laser forming equipment with the spot smaller than 100 mu m is preferable; in the design method of the invention, different materials can be selected according to the actual product requirement, for example, the requirement of heat conduction/heat dissipation/heat exchange exists, and then the metal materials with good heat conduction performance, such as aluminum alloy and copper alloy, are selected; if used in a rust-proof scenario, a titanium alloy or stainless steel material may be used. The design method of the invention can be adapted to different materials.
Preferably, the porous structure comprises a lattice unit cell structure and a three-period minimum curved surface, and the software used for modeling is selected from the group consisting of ntology and MSLattice;
preferably, the tricycled minimal surface (Triply Periodic Minimal Surface, TPMS) comprises Schoen-Gyroid, schwarz-Diamond or Schwarz-primary;
preferably, the Schoen-Gyroid, schwarz-Diamond or Schwarz-Primive comprises a sheet TPMS and a solid TPMS, respectively.
Preferably, the modeling formula of the Schoen-Gyroid is:
sin X cos Y+sin Y cos Z+sin Z cos X＝c；
preferably, the modeling formula of the Schwarz-Diamond is:
cos X cos Y cos Z-sin X sin Y sin Z＝c；
preferably, the modeling formula of Schwarz-primary is:
cos X+cos Y+cos Z＝c。
preferably, the step S2 specifically includes printing test pieces with different unit cell specifications, observing the conditions of powder clamping, surface burning, warping and collapse of the test pieces, and determining the unit cell specification without the conditions as the unit cell size range of the porous structure.
Preferably, the unit cell size is selected from 5 to 20mm.
Preferably, the different unit cell specifications are 7-10;
further preferably, the unit cell size is 7, and is 5, 7.5, 10, 12.5, 15, 17.5, 20mm respectively.
Preferably, the test pieces X, Y, Z are stacked in the same proportion in 8-10 layers of single cells in each direction, and the relative density is 25-35%.
It is further preferred that when the test piece is a disc-shaped thin plate part, the thickness direction is filled with at least 2 layers of unit cells.
If the unit cell is too small, powder clamping risk is easy to occur, and if the unit cell is too large and the supporting force is insufficient, cantilever collapse can be caused; and, for the same three-dimensional STL model data precision, the smaller the unit cell is, the larger the data volume is; the larger the unit cell, the smaller the data volume; however, for energy waves such as heat and sound, the energy waves are easily weakened by porous structures with small pore diameters and multiple layers, and the principle is that the repeated absorption and reflection of pore walls inhibit convection and radiation; based on the above theory, the present inventors found in the study that the unit cell size of 5 to 20mm can cover all the equipment, processes and materials currently on the market, so that in order to improve the efficiency, the design can be made in this range. In order to avoid the structural edge effect, at least 2 layers of single cells are required to be arranged in the thickness direction of the disc-shaped thin plate part, and 5-10 layers of single cells are selected for research in consideration of comprehensive cost and calculated amount, so that the accuracy of a result is ensured.
Preferably, the step S3 specifically includes: modeling different porous structures within the relative density range of 20-50%, arranging clamping plates on the upper side and the lower side, fixing the clamping plates on the lower side by simulation design, setting a certain normal pressure on the upper side, simulating deformation displacement and stress of the porous structure, obtaining a convergence interval of the relative density, and determining the convergence interval as the relative density range of the porous structure.
Preferably, the number of the modeled porous structures is 7-10;
further preferably, the modeled porous structures are 7, and the relative densities are 20%, 25%, 30%, 35%, 40%, 45%, 50%, respectively.
With the increase of the relative density, more materials are distributed in the space boundary, and the static mechanical properties of the porous structure are improved (deformation and stress are reduced) accordingly, but the relative density cannot be too high based on the performance consideration of light weight and the like. The inventors have found that the correlation between deformation and stress of the porous structure and the relative density converges in a specific interval in which the porous structure transitionally changes, more toward a solid structure containing isolated pores; the convergence interval is obtained by the design method of the invention, so that the most preferable porous structure relative density range can be obtained, and the weight reduction and mechanical properties of the porous structure can be balanced better in the range.
Preferably, the step S4 specifically includes screening by static compression simulation analysis, static compression experiment and static stretching experiment;
the static compression simulation analysis comprises the following steps: taking values in the unit cell sizes and the relative density ranges of S2 and S3, modeling to obtain a corresponding porous structure model, arranging clamping plates on the upper side and the lower side, fixing the clamping plates on the lower side of the simulation design, applying a certain normal pressure on the upper side, and carrying out static mechanical analysis to obtain deformation displacement, stress and stress concentration conditions;
the step of the static compression experiment (including energy absorption calculation analysis) includes: taking values in the unit cell sizes and the relative densities of the S2 and the S3, arranging clamping plates on the upper side and the lower side, printing corresponding test pieces, fixing the clamping plates on the lower side, applying a certain normal pressure on the upper side, and measuring stress and displacement values; the energy absorption condition can be analyzed through a formula or software;
the static stretching experiment comprises the following steps: taking values in the unit cell sizes and the relative density ranges of S2 and S3, and designing a stretching section; the stretching section extends towards the two ends of the stretching direction, the relative density is gradually increased, and a transition section is obtained; one end of the transition section, which is opposite to the stretching section, is connected with a solid structure as a clamping section, corresponding test pieces are printed, and yield strength and tensile strength are measured.
Preferably, the energy absorption analysis uses a software of OriginLab PriginPro.
Preferably, the test method of the static compression test is ASTM E9 or GB/T7314, and the test equipment is a universal tester;
preferably, the static tensile test is tested in accordance with ASTM E9 or GB/T228.
Preferably, each of the two directions of the cross section of the stretching section has 2-5 layers of single cells in each direction, 5-10 layers of single cells in the stretching direction, and the length of the stretching direction is more than or equal to 100mm;
preferably, the stretching direction of the transition section is 1.5-3 layers of single cells, the length of the stretching direction is 10-20 mm, and the relative density gradually increases to more than 70%;
preferably, the clamping sections can be provided with corresponding anti-friction clamping grooves according to a universal testing machine, and the length of each clamping section in the stretching direction is 50-100 mm.
The design method comprehensively considers the mechanical property requirements of multiple aspects such as compression resistance, collision resistance, tensile resistance and the like in the actual application scene of the porous structure, integrates multiple screening methods, and provides an experimental design parameter range with maximized efficiency and higher accuracy. The invention screens out the cell type with minimum stress concentration, optimal compression and energy absorption performance and maximum tensile performance in the alternative cell types through static compression simulation analysis, static compression experiment (including energy absorption calculation analysis) and static tensile experiment. The inventor finds that the problem that the connection position of the porous structure and the clamping section is directly broken easily occurs in the static stretching experiment in the research, so that the accuracy of an experiment result is influenced.
Preferably, the step S5 specifically includes modeling porous structures with different sizes and rounded corners at the joint of the porous structures and the shell, arranging clamping plates on the upper side and the lower side, fixing clamping plates on the lower side of the simulation design, applying a certain normal pressure on the upper side, detecting the maximum deformation and the maximum stress of the model, and determining the influence and parameters of the rounded corners connected with the porous structures and the shell on the static mechanical properties.
Preferably, the size of the fillets at the joint of the porous structure and the shell is selected from 1-5 mm; examples include 1mm, 2mm, 3mm, 4mm and 5mm.
According to the invention, the joint of the porous structure and the shell is easy to cause stress concentration through static mechanical simulation analysis, so that the fillet design is carried out on the joint, the fillet is beneficial to stress dispersion, the yield strength of the structure can be improved, and the problems of shrinkage, deformation, cracking and the like of the horizontal shell surface in the actual processing process are effectively solved. According to the design method provided by the invention, the fillet size can be optimized, the light weight is ensured, and meanwhile, the effective proppant connection strength is improved.
Preferably, the porous structure static mechanical analysis comprises resonance frequency analysis;
preferably, when the porous structure of the additive manufacturing is a meter-scale part, the static mechanical analysis of the porous structure further comprises a model modal analysis of a homogenized material;
preferably, the static mechanical analysis of the porous structure may further comprise a display dynamic impact simulation analysis.
Preferably, the specific steps of resonance frequency analysis include: modeling porous structures of different unit cell types, arranging clamping plates on the upper side and the lower side, respectively analyzing free modes and one-side constraint modes by using simulation software, and counting the resonant frequency of the porous structures.
Preferably, the specific step of modal analysis of the homogenized material model comprises the following steps: according to the method of homogenizing the material model, the meter-level porous structural unit cell equivalent is replaced by a 6 multiplied by 6 equivalent stiffness coefficient array, and the method is used for analyzing static force, mode and static force topology of the elastic deformation stage.
Preferably, the specific steps of the dynamic impact simulation analysis comprise: and modeling a porous structure in a 30 multiplied by 20mm spatial range, arranging clamping plates on an upper layer and a lower layer, and analyzing the effective stress distribution condition of the porous structure model by simulating and simulating that a small ball impacts the porous structure model at a speed of 80-150 mm/s.
In the steps S2 to S6, the following steps are performed:
preferably, the method comprises the steps of, the unit cell size of the porous structure is 5 multiplied by 5mm 10X 10mm or 15X 15mm; x, Y, Z, 5-10 layers of single cells are stacked in each direction in the same proportion;
preferably, the thickness of the clamping plate is 1-3 mm;
preferably, the material of the porous structure comprises titanium alloy Ti 6 Al 4 V, aluminum alloy AlSi 10 Mg or stainless steel 316L.
Further preferably, the titanium alloy Ti 6 Al 4 V has a density of 4.43g/cc, a Poisson's ratio of 0.342 and a Young's modulus of 113.8Gpa.
Preferably, the normal pressure is 10-15N;
preferably, the software used for the simulation is nTopology, abaqus or LS-DYNA;
preferably, the porous structure thermal management performance analysis in the step S7 includes a unit cell surface area analysis, a porous structure surface area and a pressure loss analysis.
Preferably, the specific step of unit cell surface area analysis comprises: fixing the relative density, modeling porous structures with different unit cell sizes, respectively calculating the contact surface area, and analyzing the degree of lifting of the contact surface area.
Preferably, the specific steps of porous structure surface area and pressure loss analysis include: fixing the unit cell size and the relative density in a space of 90 multiplied by 60 multiplied by 30mm, and calculating the contact surface area and the volume of the porous structures with different height-width ratios; the liquid flow rate of 30 to 50m/s was set and the pressure loss was analyzed.
The invention also provides a metal guard plate, which comprises a shell and an internally filled porous structure, wherein the porous structure is designed by the design method for manufacturing the porous structure by the additive;
preferably, the thickness of the shell is 1-2 mm;
preferably, the porous structure is internally filled with vacuum, air or a heat-insulating composite material;
preferably, the unit cell type of the porous structure is sheet Schoen-Gyroid or sheet Schwarz-Diamond;
preferably, the round angle for connecting the porous structure and the shell is 2-3 mm;
preferably, the method comprises the steps of, the unit cell size 15X 15mm;
preferably, the porous structure has a relative density of 25 to 35%;
preferably, the unit cell aspect ratio is 1-5: 1.
preferably, the material of the metal guard plate is aluminum alloy AlSi 10 Mg；
Preferably, the metal guard plate is used for a fighter plane body surface guard plate or a satellite recovery cover guard plate.
Compared with the prior art, the invention has the following beneficial effects:
1. the design method of the porous structure for additive manufacturing comprehensively analyzes the mechanical property and the thermal management property, and the designed porous structure can have excellent composite properties such as weight reduction, energy absorption, vibration isolation, thermal management and the like;
2. the design method has good compatibility, can be suitable for different additive manufacturing equipment, materials and processes, can be used for optimizing the production process, and is beneficial to improving the quality and the comprehensive performance of products;
3. the design method of the invention also provides a static mechanical analysis method when applied to the meter-level porous structure part, overcomes the problems that the grids which cannot be solved by super calculation are difficult to divide, the number of the grids is too large and the like, and further expands the application field of the porous structure;
4. the design method of the invention also analyzes the impact dynamics and can design and screen the porous structure required by specific application scenes such as aircraft engines and the like;
5. the design method of the invention obtains the conclusion that the flaky Schoen-Gyroid and flaky Schwarz-Diamond structures have excellent weight reduction, energy absorption, vibration isolation and thermal management composite performance in the three-period minimum curved surface unit cell type, and can be used for the design of the surface guard plate of the fighter plane body or the satellite recovery guard plate.
Drawings
FIG. 1 is a schematic diagram of the structure of a lattice BCC and a tricycled minimal surface;
FIG. 2 is a cloud chart showing the results of static compression simulation of the porous structure of the sheet Schoen-Gyroid with different relative densities in example 1;
FIG. 3 is a graph showing deformation displacement and stress statistics of the sheet-like Schoen-Gyroid porous structure of different relative densities in example 1;
FIG. 4 is a graph showing the maximum deformation (left) and maximum stress (right) statistics of the BCC and each three-period minimum curved porous structure of example 1;
FIG. 5 is a photograph of a sample of the static compression test in example 1 (1-BCC structure, 2-sheet Schoen-Gyroid, 3-sheet Schwarz-Diamond, 4-sheet Schwarz-primary);
FIG. 6 is a graph of stress versus displacement for static compression experiments in example 1 (1-BCC structure, 2-sheet Schoen-Gyroid, 3-sheet Schwarz-Diamond, 4-sheet Schwarz-primary, 2 parallel experiments of the same structure, up and down respectively);
FIG. 7 is a photograph of a sample of the static tensile test in example 1 (a-BCC structure, b-sheet Schwarz-primary, c-sheet Schwarz-Diamond, d-sheet Schoen-Gyroid);
FIG. 8 is a photograph of samples from the static tensile test in example 1 (1-BCC structure, 2-sheet Schoen-Gyroid, 3-sheet Schwarz-Diamond, 4-sheet Schwarz-primary, 3 samples from each group are 3 parallel experiments of the same structure);
FIG. 9 is a diagram showing the BCC structure of example 1 without rounded corners, 1mm, 2mm, 3mm rounded corners, respectively, with the splints;
FIG. 10 is a diagram showing the BCC structure of example 1 without rounded corners, 1mm, 2mm, 3mm rounded corners, respectively, with the splints;
FIG. 11 is a schematic diagram showing the sheet-like Schoen-Gyroid structure of example 1 without rounded corners, 1mm, 2mm, 3mm rounded corners, respectively, with the splints;
FIG. 12 is a graph of static mechanical analysis of the BCC and sheet-like Schoen-Gyroid structures of example 1 with no rounded corners and 1mm rounded corners, respectively;
FIG. 13 is a graph of the free mode resonance frequencies of the 7-10 order in example 1;
FIG. 14 is a plot of the 1 st order side-constrained modal resonance frequency of example 1;
FIG. 15 is a graph showing the effective stress distribution of BCC (left) and sheet Schoen-Gyroid (right) porous structure models in kinetic impact simulation analysis in example 1;
FIG. 16 is a modeling graph of the surface area of the porous structure and the different aspect ratios of the sheet-like Schoen-Gyroid porous structure in the pressure loss analysis of example 1;
FIG. 17 is a modeling plot of the surface area of the porous structure and the different aspect ratios of the sheet-like Schwarz-Diamond porous structure in the pressure loss analysis of example 1;
fig. 18 is a modeling diagram of the metal shield of example 1.
Detailed Description
The present invention will be described in further detail with reference to the following specific examples, to which the present invention is not limited.
Example 1
The embodiment provides a design method of an additive manufacturing porous structure, which comprises the following steps:
s1: fixing additive manufacturing equipment, materials and process parameters, and selecting unit cell types of a porous structure for modeling: a laser forming device with a light spot smaller than 100 μm is fixed, a fixed profile offset is combined with a single-path scanning mode, a manufacturing process is selective laser melting (selected laser melting, SLM), a fixed printing layer thickness is 30 μm, a fixed scraper system is a flexible scraper system, and a fixed material is selected from titanium alloy Ti 6 Al 4 V, aluminum alloy AlSi 10 Mg and stainless steel 316L, fixed sieving powder mixing specification; selecting a tricycled minimum curved surface as a unit cell type of a porous structure, and taking a BCC body-centered cubic (body-centered cubic) as a comparison reference; using the nTopologyModeling (as shown in fig. 1);
s2: determining the unit cell size range of the porous structure: using S1 fixed additive manufacturing equipment and parameters, printing porous structure test pieces with single cell specifications of 5, 7.5, 10, 12.5, 15, 17.5 and 20mm respectively, observing the conditions of powder clamping, surface burning, warping and collapse of the test pieces, and determining the single cell size range of the porous structure when the single cell specifications of 5-15 mm are not found;
the test piece X, Y, Z has the same proportion of 10 layers of single cells in each direction, and the relative density is 30%;
s3: determining the relative density range of the porous structure: the fixed unit cell type is sheet Schoen-Gyroid, different porous structures are modeled by using nTopology software according to relative densities of 20%, 25%, 30%, 35%, 40%, 45% and 50%, the unit cell size is 5 multiplied by 5mm, the directions of X and Y, Z are in the same proportion, 4 layers of unit cells in each direction are stacked, clamping plates with the thickness of 1mm are arranged on the upper side and the lower side, and the material type is Ti 6 Al 4 V (density 4.43g/cc, poisson's ratio 0.342, young's modulus 113.8 Gpa); the method comprises the steps of simulating and designing a lower side splint to fix by using a nTopology software, setting a normal pressure of 10N on the upper side (shown in figure 2), counting deformation displacement and stress of a porous structure, drawing a change chart (shown in figure 3), and determining the relative density range of the porous structure by considering an error range and obtaining a convergence interval of 25-35% of the relative density when the relative density is more than 30%;
s4: screening the unit cell type of the porous structure:
(1) Static compression simulation analysis: taking values in the unit cell sizes and relative density ranges of S2 and S3, wherein the unit cell sizes are 5 multiplied by 5mm, the relative density is 25 percent, the unit cells in the directions of X, Y, Z are in the same proportion, 4 layers of unit cells in each direction are stacked, clamping plates with the thickness of 1mm are arranged on the upper side and the lower side, and the material types are Ti 6 Al 4 V (density 4.43g/cc, poisson's ratio 0.342, young's modulus 113.8 Gpa), single cell types of BCC, sheet Schoen-Gyroid, sheet Schwarz-Diamond, sheet Schwarz-Primive, solid Schoen-Gyroid, solid Schwarz-Diamond, solid Schwarz-Primive, and corresponding porous structure model were obtained by modelingThe method comprises the steps of carrying out a first treatment on the surface of the The method comprises the steps of simulating and designing the fixation of a lower side clamping plate by using the nTopology software, setting a normal pressure of 10N on the upper side, and displaying that stress concentration occurs in a large range at a node of the BCC structure, and the stress concentration occurs only at the joint of the sheet-shaped Schoen-Gyroid structure and the clamping plate; the maximum deformation and the maximum stress of each porous structure are respectively plotted (as shown in fig. 4), and the result shows that the entity Primive has obvious stress concentration, and a node fracture mode of a lattice type is presented in compression, so that the sheet TPMS has no stress concentration problem, and the static mechanical properties of the sheet Schoen-Gyroid and the sheet Schwarz-Diamond are optimal;
(2) Static compression experiment: taking values in the unit cell sizes and relative densities of S2 and S3, wherein the unit cell sizes are 5 multiplied by 5mm, the relative densities are 25 percent, X, Y, Z three directions are in the same proportion, 10 layers of unit cells in each direction are stacked, clamping plates with the thickness of 1mm are arranged on the upper side and the lower side of the unit cell, the material type is SS316L (the density is 8.0g/cc, the Poisson ratio is 0.28, the Young modulus is 193 Gpa), the unit cell types are BCC, sheet Schoen-Gyroid, sheet Schwarz-Diamond and sheet Schwarz-Pritive respectively, and corresponding test pieces (shown in figure 5) are printed by using S1 fixed additive manufacturing equipment and parameters, and 2 parallel test pieces are printed on each structure; using a universal tester, measuring stress and displacement values according to the GB/T7314 method, drawing a stress-displacement relationship graph (shown in figure 6), performing energy absorption analysis by using OriginLab PriginPro software, and recording data in Table 1;
TABLE 1
From the results, the static compression performance of the sheet Schoen-Gyroid and the sheet Schwarz-Diamond is optimal;
(3) Static tensile test: the stretching section is designed by taking values in the unit cell sizes and relative densities of S2 and S3, wherein the unit cell size is 10 multiplied by 10mm, the relative density is 25 percent, ti 6 Al 4 V (density 4.43g/cc, poisson's ratio 0.342, young's modulus 113.8 Gpa), 2 layers of unit cells in each of two directions of the cross section of the stretching section of the porous structure, 10 layers of unit cells in the stretching direction, and length of 100mm in the stretching direction; the stretching sections extend towards the two ends of the stretching direction, the relative density is gradually increased from 25% to 60%, transition sections are obtained, and the length of each transition section in the stretching direction is 15mm; one end of the transition section opposite to the stretching section is connected with a solid structure as a clamping section, the clamping sections at the two ends are 74.17mm each, the cross section of the clamping section is 25 multiplied by 25mm, and the R angle is 5mm; according to the design, using S1 fixed additive manufacturing equipment and parameters, printing corresponding test pieces (shown in FIG. 7), and printing 3 parallel samples for each structure; the yield strength and tensile strength were measured according to GB/T228 method using a universal tester, the results are shown in Table 2, and a photograph of the test piece after stretching is shown in FIG. 8;
TABLE 2
| Yield strength/MPa | Tensile strength/MPa | |
| BCC | 145 | 192 |
| Sheet-like Schoen-Gyroid | 302 | 388 |
| Sheet-like Schwarz-Diamond | 383 | 422 |
| Sheet-like Schwarz-Primitive | 269 | 328 |
From the data, the tensile properties of the sheet Schoen-Gyroid and sheet Schwarz-Diamond structures are better;
from the above conclusion, the cell type of the porous structure was determined to be either sheet Schoen-Gyroid or sheet Schwarz-Diamond;
s5: designing a rounded corner for connecting the porous structure with the shell: taking values in the unit cell sizes and relative density ranges of S2 and S3, fixing the unit cell sizes to be 5 multiplied by 5mm, and the relative density to be 25 percent, wherein the unit cells in the directions of X, Y, Z are in the same proportion, 4 layers of unit cells in each direction are stacked, clamping plates with the thickness of 1mm are arranged on the upper side and the lower side, and the material types are Ti 6 Al 4 V (density is 4.43g/cc, poisson ratio is 0.342, young's modulus is 113.8 Gpa), fixed unit cell types are BCC and sheet Schoen-Gyroid respectively, the sizes of fillets at the joint of a porous structure and a shell are 0, 1, 2 and 3mm (shown in figures 9 and 10), models of 0mm and 1mm of fillets are simulated through nTopology software modeling, lower side clamping plate fixing is simulated, normal pressure of 10N is applied to the upper side, static analysis is carried out (shown in figure 11), the maximum deformation and the maximum stress of the models are detected (shown in figure 12), and the influence and parameters of the fillets of the connection of the porous structure and the shell on static mechanical properties are determined;
s6: static mechanical analysis of porous structure:
(1) Resonance frequency analysis: taking values in the unit cell sizes and relative density ranges of S2 and S3, wherein the unit cell sizes are 5 multiplied by 5mm, the relative density is 25 percent, the unit cells in the directions of X, Y, Z are in the same proportion, 4 layers of unit cells in each direction are stacked, clamping plates with the thickness of 1mm are arranged on the upper side and the lower side, and the material types are Ti 6 Al 4 V (density 4.43g/cc, poisson's ratio 0.342, young's modulus 113.8 Gpa), unit cell types BCC, schoen-Gyroid, schwarz-Diamond and Schwarz-Primive, respectively, were modeled by the nTopology software, and free mode were performed using nTopology, respectivelyOne-side constraint mode analysis is performed, the resonance frequency is counted, a 7-10-order free mode resonance frequency curve is shown in fig. 13, and a 1-order one-side constraint mode resonance frequency curve is shown in fig. 14; it can be seen from the figure that the first-order constraint and the seven-order free frequency of the sheet Schoen-Gyroid and the sheet Schwarz-Diamond are higher, and the frequency required for generating resonance is higher;
(2) Homogenizing material model modal analysis: according to the homogenization material model method, porous structure unit cells with unit cell types of BCC, sheet Schoen-Gyroid, sheet Schwarz-Diamond and sheet Schwarz-primary are replaced by 6 multiplied by 6 equivalent stiffness coefficient arrays respectively at the relative density of 25%, and the homogenization material model is obtained by counting the unit cells into a table 3, and the static force, the mode and the static force topology of the elastic deformation stage are analyzed according to the homogenization material model.
TABLE 3 Table 3
(3) Dynamic impact simulation analysis is shown: modeling a porous structure in a 30X 20mm spatial range, wherein the unit cell size of the porous structure is 5X 5mm, the relative density is 25%, clamping plates with the thickness of 1mm are arranged on the upper side and the lower side, and the material type is Ti 6 Al 4 V (density 4.43g/cc, poisson's ratio 0.342, young's modulus 113.8 Gpa), unit cell type BCC, sheet Schoen-Gyroid, using nTopology software modeling, LS-DYNA simulation to simulate a 10mm diameter pellet striking the upper side of the porous structure model at 100mm/s speed, analysis of effective stress distribution (as shown in FIG. 15); as can be seen from the figure, the effective stress distribution of the sheet-like Schoen-Gyroid structure is more uniform, and the porous materials share the impact load together;
s7: analysis of heat management performance of porous structure:
(1) Unit cell surface area analysis: fixed relative densities were 30%, unit cell sizes were 5, 10, 15mm, and unit cell types were BCC, schoen-Gyroid and Schwarz-Diamond, respectively, modeled using the ntology software, and contact surface areas were calculated, as shown in table 4;
TABLE 4 Table 4
Analyzing the degree of contact surface area improvement, compared with BCC, the porous structure contact surface areas of the flaky Schoen-Gyroid and the flaky Schwarz-Diamond are respectively improved by 64 percent and 93 percent, and the larger contact surface area is beneficial to heat exchange and heat dissipation;
(2) Porous structure surface area and pressure loss analysis: in a space of 90X 60X 30mm, the fixed unit cell size is 15mm, the relative density is 30%, and the aspect ratio is 1: 1. 2:1 and 5:1, wherein the unit cell types are respectively sheet Schoen-Gyroid (shown in figure 16) and sheet Schwarz-Diamond (shown in figure 17), the wall thickness of the porous structure of the sheet Schoen-Gyroid is 1mm, and the wall thickness of the porous structure of the sheet Schwarz-Diamond is 0.835mm; modeling by using the nTopology software, calculating the contact surface area and volume, performing simulation by using the Ansys FLUENT software, setting the incidence speed of 40m/s, analyzing the pressure loss, and recording in tables 5 and 6;
TABLE 5
TABLE 6
As can be seen from the data, at aspect ratio 2:1, the porous structures of the sheet Schoen-Gyroid and the sheet Schwarz-Diamond have better surface area and pressure loss, and the aspect ratio is increased to 5: at 1, the lifting is not obvious.
Another aspect of this embodiment provides a metal shield comprising a housing and an internally filled porous structure(as shown in fig. 18), wherein the porous structure is designed by the design method of additive manufacturing porous structure described above; the material is aluminum alloy AlSi 10 Mg, the thickness of the shell is 1mm, the type of a unit cell of the internally filled porous structure is a sheet Schoen-Gyroid structure, the unit cell size is 15 multiplied by 15mm, the wall thickness is 1mm, the size of a fillet at the joint of the porous structure and the shell is 3mm, and the unit cell aspect ratio is 2:1, filling the inside of a porous structure with cooling liquid; the metal guard board is used for the surface guard board of the fighter plane body.
Claims (10)
1. A design method for additive manufacturing porous structures, comprising the steps of:
s1: fixing additive manufacturing equipment, materials and process parameters, and selecting unit cell types of a porous structure for modeling;
s2: determining the unit cell size range of the porous structure;
s3: determining the relative density range of the porous structure;
s4: screening the single cell type of the porous structure;
s5: designing a round angle for connecting the porous structure with the shell;
s6: static mechanical analysis of the porous structure;
s7: and analyzing the heat management performance of the porous structure.
2. The method of claim 1, wherein the step S1 of fixing the additive manufacturing equipment, materials and process parameters comprises: fixing an additive manufacturing device, fixing a set of laser process parameters, fixing a printing layer thickness, fixing a scraper system, fixing materials and fixing powder sieving and mixing specifications.
3. The method of claim 1, wherein the porous structure in step S1 comprises a lattice cell structure and a tricycled minimum curved surface, and the modeling software is selected from the group consisting of ntpology and MSLattice.
4. The method according to claim 1, wherein the step S2 is specifically to print test pieces with different unit cell sizes, observe conditions of powder sticking, surface scorching, warping and collapse of the test pieces, and determine a unit cell size range of the porous structure when the unit cell sizes are not found.
5. The method for designing an additive manufacturing porous structure according to claim 1, wherein the step S3 specifically includes: modeling different porous structures within the relative density range of 20-50%, arranging clamping plates on the upper side and the lower side, fixing the clamping plates on the lower side by simulation design, setting a certain normal pressure on the upper side, simulating deformation displacement and stress of the porous structure, obtaining a convergence interval of the relative density, and determining the convergence interval as the relative density range of the porous structure.
6. The method for designing an additive manufacturing porous structure according to claim 1, wherein the step S4 specifically includes screening by static compression simulation analysis, static compression experiments, and static stretching experiments;
the static compression simulation analysis comprises the following steps: taking values in the unit cell sizes and the relative density ranges of S2 and S3, modeling to obtain a corresponding porous structure model, arranging clamping plates on the upper side and the lower side, fixing the clamping plates on the lower side of the simulation design, applying a certain normal pressure on the upper side, and carrying out static mechanical analysis to obtain deformation displacement, stress and stress concentration conditions;
the static compression experiment comprises the following steps: taking values in the unit cell sizes and the relative densities of the S2 and the S3, arranging clamping plates on the upper side and the lower side, printing corresponding test pieces, fixing the clamping plates on the lower side, applying a certain normal pressure on the upper side, and measuring stress and displacement values; the energy absorption condition can be analyzed through a formula or software;
the static stretching experiment comprises the following steps: taking values in the unit cell sizes and the relative density ranges of S2 and S3, and designing a stretching section; the stretching section extends towards the two ends of the stretching direction, the relative density is gradually increased, and a transition section is obtained; one end of the transition section, which is opposite to the stretching section, is connected with a solid structure as a clamping section, corresponding test pieces are printed, and yield strength and tensile strength are measured.
7. The method according to claim 1, wherein the step S5 specifically includes modeling the porous structure of the rounded corner at the junction of the porous structure and the shell, arranging clamping plates on the upper side and the lower side, fixing clamping plates on the lower side of the simulated design, applying a certain normal pressure on the upper side, detecting the maximum deformation and the maximum stress of the model, and determining the influence and the parameters of the rounded corner of the porous structure and the shell on the static mechanical property.
8. The method of claim 1, wherein when the porous structure is a meter-scale part, the static mechanical analysis of the porous structure further comprises a model modal analysis of a homogenized material.
9. The method of designing a porous structure for additive manufacturing according to claim 1, wherein the porous structure thermal management performance analysis in step S7 includes a unit cell surface area analysis, a porous structure surface area and a pressure loss analysis.
10. A metal guard plate, characterized by comprising a casing and an internally filled porous structure designed by the design method of additive manufacturing porous structure according to any one of claims 1 to 9;
preferably, the thickness of the shell is 1-2 mm, the unit cell type of the porous structure is a sheet Schoen-Gyroid or sheet Schwarz-Diamond structure, the interior of the porous structure is filled with vacuum, air or heat insulation composite materials, the round angle for connecting the porous structure and the shell is 2-3 mm, and the unit cell aspect ratio is 1-2: 1.
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| CN117156688B (en) * | 2023-10-27 | 2024-01-12 | 深圳市常丰激光刀模有限公司 | Laser drilling method for multilayer circuit board |
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