CN108197384B - Parameter optimization method of powder laser 3D printing forming process - Google Patents
Parameter optimization method of powder laser 3D printing forming process Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 161
- 230000008569 process Effects 0.000 title claims abstract description 137
- 239000000843 powder Substances 0.000 title claims abstract description 58
- 238000010146 3D printing Methods 0.000 title claims abstract description 26
- 238000005457 optimization Methods 0.000 title claims abstract description 14
- 229910052751 metal Inorganic materials 0.000 claims abstract description 10
- 239000002184 metal Substances 0.000 claims abstract description 10
- 238000000465 moulding Methods 0.000 claims abstract description 7
- 238000004364 calculation method Methods 0.000 claims description 101
- 239000000463 material Substances 0.000 claims description 37
- 230000000704 physical effect Effects 0.000 claims description 30
- 229910045601 alloy Inorganic materials 0.000 claims description 11
- 239000000956 alloy Substances 0.000 claims description 11
- 238000002940 Newton-Raphson method Methods 0.000 claims description 4
- 238000010521 absorption reaction Methods 0.000 claims description 4
- 238000013386 optimize process Methods 0.000 claims description 4
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- 230000007547 defect Effects 0.000 abstract description 3
- 230000035882 stress Effects 0.000 description 40
- 238000005516 engineering process Methods 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910000881 Cu alloy Inorganic materials 0.000 description 2
- YOCUPQPZWBBYIX-UHFFFAOYSA-N copper nickel Chemical compound [Ni].[Cu] YOCUPQPZWBBYIX-UHFFFAOYSA-N 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 239000000654 additive Substances 0.000 description 1
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- 238000006243 chemical reaction Methods 0.000 description 1
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- 238000005242 forging Methods 0.000 description 1
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- 238000002844 melting Methods 0.000 description 1
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- 238000012545 processing Methods 0.000 description 1
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- 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]
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
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Abstract
The invention relates to a parameter optimization method for a powder laser 3D printing and forming process. The method comprises the steps of utilizing a computer finite element program to analyze and calculate the temperature, stress and strain field of metal powder during molding under different process parameters, tracking the stress and strain value in the part printing process, predicting the deformation and defects of the molded part under different process parameters, and then quickly optimizing the existing process parameters according to the analysis result to quickly obtain the optimal process parameters of powder molding.
Description
Technical Field
The invention relates to the technical field of powder laser additive manufacturing, in particular to a parameter optimization method of a powder laser 3D printing forming process.
Background
3D printing is originated from rapid prototyping manufacturing technology, and with the rise of metal material 3D printing technology, 3D printing is gaining wide attention on a global scale. Compared with the traditional casting technology, the 3D printing technology does not need to prepare a mold, and the research and development period is shortened. The 3D printing technology can provide mechanical properties which are comparable to those of a forging technology, meanwhile, the forming of a complex structural part is realized, and the blank of the traditional processing technology is filled.
Although the 3D printing technology has many technical advantages, it is critical to select appropriate printing process parameters, and different process parameters have great influence on a formed part, such as different molten pools generated by different scanning speeds, laser powers, overlapping ratios, and the like, which indirectly causes different properties of the formed part, and improper process parameter selection may also affect the properties of a part, such as excessive thermal stress and large thermal deformation, which may cause failure in forming the part in a severe case. The selection of the process parameters of the traditional 3D printing technology needs a process engineer to determine the process parameters through a large number of process experiments, the process parameters are more, the test period is long, the cost is high, and the application range of the process parameters obtained through testing to the powder is narrow.
Disclosure of Invention
Based on this, it is necessary to provide a parameter optimization method for a powder laser 3D printing and forming process, which can quickly optimize process parameters.
A parameter optimization method for a powder laser 3D printing forming process comprises the following steps:
establishing a three-dimensional model of the molded part, and dispersing the three-dimensional model of the molded part into a finite element calculation model;
establishing selectable parameter ranges of a plurality of process parameters and physical properties of materials;
selecting a plurality of discrete process parameter values within a selectable parameter range for any one of the process parameters;
converting the discrete process parameter values into a plurality of calculation working conditions and a plurality of heat source loads;
obtaining a temperature field calculation model of the formed part under each discrete process parameter value;
obtaining a stress field calculation model and a strain field calculation model of the formed part under each discrete process parameter value;
analyzing the temperature field calculation model, the stress field calculation model and the strain field calculation model obtained under each discrete process parameter value to obtain an optimized process parameter value;
and performing iterative calculation by taking the minimum stress and strain of the formed part as a target to obtain the optimal process parameter value.
In one embodiment, the step of establishing the selectable parameter ranges of the plurality of process parameters and the physical properties of the material comprises the thickness of the powder to be spread, the laser power, the laser scanning width, the scanning mode, the scanning speed, the spot radius and the overlapping ratio.
In one embodiment, in the step of establishing the selectable parameter ranges for the plurality of process parameters and the physical properties of the material, the factors that establish the selectable parameter ranges for the plurality of process parameters include powder material, powder particle size, powder shape, and structural shape of the molded part.
In one embodiment, in the step of establishing the selectable parameter ranges for the plurality of process parameters and the physical properties of the material, the physical properties of the material include thermal conductivity, specific heat capacity, density, enthalpy, elastic modulus, yield strength, poisson's ratio, and linear expansion coefficient.
In one embodiment, in the step of establishing the selectable parameter ranges for the plurality of process parameters and the physical properties of the material:
if the material is single-phase powder, the physical property of the material is the inherent physical property of the metal single phase;
if the material is alloy powder, the physical property of the material is expressed by the formulaCalculated, wherein x is of an alloyPhysical Property, rn、xnRespectively the concentration and physical properties of certain components in the alloy.
In one embodiment, the step of converting the plurality of discrete process parameter values into the plurality of calculated operating conditions and the plurality of heat source loads further comprises the steps of:
determining the type of the element adopted by finite element calculation according to the material and the molding process parameters;
wherein the cell type is a cell type containing displacement and temperature degrees of freedom.
In one embodiment, in the step of converting the plurality of discrete process parameter values into the plurality of calculated operating conditions and the plurality of heat source loads, the heat source loads are calculated by a formulaCalculated, wherein Q is laser power, eta is absorption coefficient of the powder to the laser, r0Is the spot radius and r is the distance from the point to the center of the laser spot.
In one embodiment, the step of obtaining a stress field calculation model and a strain field calculation model of the molded part under each discrete process parameter value further includes:
reading a plurality of temperature data in the temperature field calculation model;
setting the elastic modulus and the yield strength value of the unformed powder by taking the plurality of temperature data as the load of stress calculation, and applying the calculation working condition;
a plurality of stress data are obtained by adopting a Newton-Raphson method in mathematics;
obtaining a stress field calculation model of the molded part through a plurality of stress data;
and obtaining a stress field calculation model of the formed part under each discrete process parameter value.
In one embodiment, the step of obtaining a stress field calculation model of the formed part at each discrete process parameter value further includes:
converting the plurality of stress data into a plurality of strain data;
obtaining a strain field calculation model of the formed part through a plurality of strain data;
and obtaining a strain field calculation model of the formed part under each discrete process parameter value.
In one embodiment, the step of reading a plurality of temperature data in the temperature field calculation model includes a depth of a molten pool, a width of the molten pool, a maximum temperature, a change of a temperature field with time during a part forming process, and a solidification process of the molten pool.
In the parameter optimization method of the powder laser 3D printing forming process, a computer finite element program is utilized to analyze and calculate the temperature, stress and strain field of metal powder when the metal powder is formed under different process parameters, track the stress and strain value in the part printing process, predict the deformation and defects of the formed part under different process parameters, and then quickly optimize the existing process parameters according to the analysis result to quickly obtain the optimal process parameters of the powder forming.
Drawings
FIG. 1 is a flow chart of a parameter optimization method of a powder laser 3D printing forming process according to an embodiment;
FIG. 2 is a flowchart of S700 shown in FIG. 1;
FIG. 3 is a finite element model of a built molded part of an embodiment;
FIG. 4 is a temperature field calculation model for the formed part shown in FIG. 3 at 10% overlap;
FIG. 5 is a stress field calculation model for the formed part shown in FIG. 3 at 10% overlap;
FIG. 6 is a strain field calculation model for the formed part shown in FIG. 3 at 10% overlap;
FIG. 7 is a temperature field calculation model for the formed part shown in FIG. 3 at 20% overlap;
FIG. 8 is a stress field calculation model for the formed part shown in FIG. 3 at 20% overlap;
FIG. 9 is a strain field calculation model for the formed part shown in FIG. 3 at 20% overlap;
FIG. 10 is a temperature field calculation model for the molded part shown in FIG. 3 at 30% overlap;
FIG. 11 is a model of stress field calculations for the formed part shown in FIG. 3 at 30% overlap;
FIG. 12 is a strain field calculation model for the formed part shown in FIG. 3 at 30% overlap.
Detailed Description
To facilitate an understanding of the invention, the invention will now be described more fully with reference to the accompanying drawings. Preferred embodiments of the present invention are shown in the drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
It will be understood that when an element is referred to as being "secured to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for illustrative purposes only and do not represent the only embodiments.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
As shown in fig. 1 and fig. 2, a method for optimizing parameters of a powder laser 3D printing and forming process according to an embodiment of the present invention includes the following steps.
S100, establishing a three-dimensional model of the molded part, and dispersing the three-dimensional model of the molded part into a finite element calculation model.
Firstly, establishing a three-dimensional CAD model of a target forming part, and then dispersing the three-dimensional CAD model of the forming part into a finite element calculation model by using a computer finite element program. The computer finite element program may be of the type capable of finite element analysis such as Ansys.
S200, establishing selectable parameter ranges of a plurality of process parameters and physical properties of materials.
The multiple process parameters comprise process parameters such as the thickness of the powder to be spread, the laser power, the laser scanning width, the scanning mode, the scanning speed, the spot radius and the lap joint rate. For each process parameter, there is a selectable parameter range, and the influencing factors of the selectable parameter range of each process parameter include powder material, powder particle size, powder shape and structure shape of the formed part.
The physical properties of the material need to be determined corresponding to the manufacturing material of the molded part, and the physical properties of the material need to be obtained comprise a thermal conductivity coefficient, a specific heat capacity, a density, an enthalpy value, an elastic modulus, a yield strength, a Poisson's ratio and a linear expansion coefficient. If the material is metal single-phase powder, the physical property of the material is the inherent physical property of the metal single phase. If the material is alloy powder, the physical property of the material is expressed by the formulaCalculated, wherein x is the physical property of the alloy, rn、xnRespectively the concentration and physical properties of certain components in the alloy. For example, if the material is an alloy of aluminum and iron, the thermal conductivity of the material is equal to the concentration of aluminum × the thermal conductivity of aluminum + the concentration of iron × the thermal conductivity of iron.
S300, selecting a plurality of discrete process parameter values in the optional parameter range of any process parameter.
After the selectable parameter ranges for the plurality of process parameters are determined, for each process parameter, a plurality of discrete process parameter values are selected within the selectable parameter ranges. For example, for the process parameter of the lap joint rate, if the determined optional parameter range is 10% to 30%, three discrete process parameter values of 10%, 20% and 30% can be selected within the range, and the selection number of the discrete process parameter values is not limited.
S400, determining the type of the element adopted by finite element calculation according to the material and the molding process parameters.
And selecting a corresponding unit type in a computer finite element program according to the corresponding material and the corresponding process parameter, wherein the unit type is the unit type with the freedom degrees of displacement and temperature.
500, converting the plurality of discrete process parameter values into a plurality of calculated operating conditions and a plurality of heat source loads.
And inputting a plurality of selected discrete process parameter values in a finite element program of the computer, thereby obtaining a plurality of calculation working conditions and heat source loads corresponding to the calculation working conditions one by one.
Wherein, under the corresponding calculation working condition, the heat source load passes through the formulaCalculated, wherein Q is laser power, eta is absorption coefficient of the powder to the laser, r0Is the spot radius and r is the distance from the point to the center of the laser spot.
S600, obtaining a temperature field calculation model of the formed part under each discrete process parameter value.
And (4) loading the calculated working condition and the heat source load obtained by converting each discrete process parameter on a finite element calculation model of the formed part to obtain a temperature field calculation model corresponding to the discrete process parameter. And the temperature field calculation model records relevant temperature data of the formed part. Wherein the temperature data comprises the depth of a molten pool, the width of the molten pool, the highest temperature, the change of a temperature field along with time in the forming process of the part and the solidification process of the molten pool.
S700, obtaining a stress field calculation model and a strain field calculation model of the formed part under each discrete process parameter value.
And converting the temperature field calculation model corresponding to each discrete process parameter value to obtain a stress field calculation model and a strain field calculation model corresponding to each discrete process parameter value, and converting the plurality of temperature field calculation models obtained by the plurality of discrete process parameters to obtain a plurality of stress field calculation models and a plurality of strain field calculation models.
Specifically, in S700, the step of obtaining a stress field calculation model and a strain field calculation model of the molded part under each discrete process parameter value further includes the following steps.
And S710, reading a plurality of temperature data in the temperature field calculation model.
And S720, setting the elastic modulus and the yield strength value of the unformed powder by taking the plurality of temperature data as the load for stress calculation, and applying the calculation working condition.
It should be noted that the modulus of elasticity and yield strength of the unformed powder need to be set to small values, which are negligible with respect to the physical entity.
And S730, obtaining a plurality of stress data by adopting a Newton-Raphson method in mathematics.
For each temperature data, a Newton-Raphson method in mathematics is adopted to obtain corresponding stress data, and for a plurality of temperature data, a plurality of stress data can be obtained.
And S740, obtaining a stress field calculation model of the formed part according to the plurality of stress data.
And loading the obtained multiple stress data on a finite element calculation model of the molded part to obtain a stress field calculation model of the molded part.
And S750, obtaining a stress field calculation model of the formed part under each discrete process parameter value.
And converting the temperature field calculation models corresponding to the discrete process parameter values one by one to obtain stress field calculation models corresponding to the discrete process parameter values one by one.
And S760, converting the stress data into strain data.
A plurality of stress-strain conversions are performed on the plurality of stress data obtained in step S730, so that a plurality of strain data can be obtained.
S770, obtaining a strain field calculation model of the formed part through the plurality of strain data.
And loading the obtained multiple strain data on a finite element calculation model of the molded part to obtain a strain field calculation model of the molded part.
And S780, obtaining a strain field calculation model of the formed part under each discrete process parameter value.
And converting the strain field calculation models corresponding to the discrete process parameter values one by one to obtain the strain field calculation models corresponding to the discrete process parameter values one by one.
S800, analyzing a temperature field calculation model, a stress field calculation model and a strain field calculation model obtained under each discrete process parameter value to obtain an optimized process parameter value;
and comparing the plurality of temperature field calculation models obtained by the plurality of discrete process parameter values, comparing the plurality of stress field calculation models, and comparing the plurality of strain field calculation models to obtain the process parameter value which realizes a better process effect in the plurality of discrete process parameter values.
And S900, performing iterative calculation by taking the minimum stress and strain of the formed part as a target to obtain an optimal process parameter value.
And performing iterative calculation by taking the minimum stress and strain of the formed part as a target, obtaining a better process parameter value in an optional parameter range for each process parameter through S200 to S800, further determining a better process parameter range for the better process parameter value selected by each process parameter, and obtaining an optimal process parameter value through S200 to S800.
In the parameter optimization method of the powder laser 3D printing forming process, a computer finite element program is utilized to analyze and calculate the temperature, stress and strain field of metal powder when the metal powder is formed under different process parameters, track the stress and strain value in the part printing process, predict the deformation and defects of the formed part under different process parameters, and then quickly optimize the existing process parameters according to the analysis result to quickly obtain the optimal process parameters of the powder forming.
As shown in fig. 3 to 12, taking laser 3D printing of high temperature nickel-copper alloy powder to form a long plate part as an example, a three-dimensional model of the long plate is constructed on a substrate, and the optimal forming process parameters of the alloy powder are analyzed by the above parameter optimization method.
Determining the technological parameter range of the molded part, wherein the laser power is 500-1500W, the absorption coefficient of the powder to laser is 0.2, the powder spreading thickness is greater than 20um, the scanning width is 0.1-1 mm, the spot radius is 0.1mm, the scanning speed is greater than 0.01m/s, and the lap joint rate is 10-30%.
Since a certain overlapping ratio is required between adjacent scan lines to improve the bonding between different scan lines. And selecting the determined laser power value of 500w, the scanning speed of 0.5m/s, the scanning width of 0.1mm and the spot radius of 0.1 mm. Within the selectable parameter range of the lap joint rate, selecting 10 percent, 20 percent and 30 percent of discrete process parameter values, and analyzing the optimal lap joint rate of the formed alloy part.
And in a finite element program of a computer, obtaining a temperature field calculation model, a stress field calculation model and a strain field calculation model corresponding to three discrete process parameter values. As shown in fig. 5, 6, 8, 9, 11, and 12, by comparing the three stress field calculation models and the three strain field calculation models, it can be obtained that the higher the lap joint rate is, the larger the deformation is, and therefore the minimum value of 10% should be selected for the lap joint rate. As shown in fig. 4, 7 and 10, by comparing the three temperature field calculation models, it can be seen that, considering that the lower the temperature of the molten pool, the lower the overlapping rate and the lower the temperature field, and that at the overlapping rate of 10%, a small portion of the powder at the edge of the scanning line does not reach the melting temperature, and the overlapping rate of 10% is not suitable, so that the overlapping rate of 20% is a suitable parameter.
The 20% lapping rate can be further optimized by the parameter optimization method to obtain better parameters, and similarly, other parameters such as scanning speed, laser power and the like can be optimized in such a way to obtain optimal process parameter values.
The parameter optimization method can optimize the process parameters of the printed nickel-copper alloy molded part, and can be used for integrated molding of large parts, so that the printed part has good physical properties, and the density can reach more than 98%.
The technical features of the embodiments described above may be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the embodiments described above are not described, but should be considered as being within the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (10)
1. A parameter optimization method for a powder laser 3D printing forming process is characterized by comprising the following steps:
establishing a three-dimensional model of the molded part, and dispersing the three-dimensional model of the molded part into a finite element calculation model;
establishing selectable parameter ranges of a plurality of process parameters and physical properties of materials;
selecting a plurality of discrete process parameter values within a selectable parameter range for any one of the process parameters;
converting the discrete process parameter values into a plurality of calculation working conditions and a plurality of heat source loads;
obtaining a temperature field calculation model of the formed part under each discrete process parameter value;
obtaining a stress field calculation model and a strain field calculation model of the formed part under each discrete process parameter value;
analyzing the temperature field calculation model, the stress field calculation model and the strain field calculation model obtained under each discrete process parameter value to obtain an optimized process parameter value;
and performing iterative calculation by taking the minimum stress and strain of the formed part as a target to obtain the optimal process parameter value.
2. The method for optimizing parameters of a powder laser 3D printing and forming process according to claim 1, wherein in the step of establishing the selectable parameter ranges of a plurality of process parameters and the physical properties of the material, the plurality of process parameters include a planned powder laying thickness, a laser power, a laser scanning width, a scanning mode, a scanning speed, a spot radius and an overlapping ratio.
3. The method of claim 2, wherein in the step of establishing the selectable parameter ranges of the plurality of process parameters and the physical properties of the material, the factors establishing the selectable parameter ranges of the plurality of process parameters include powder material, powder particle size, powder shape, and structural shape of the molded part.
4. The method of claim 1, wherein in the step of establishing the selectable parameter ranges for the plurality of process parameters and the physical properties of the material, the physical properties of the material include thermal conductivity, specific heat capacity, density, enthalpy, elastic modulus, yield strength, poisson's ratio, and linear expansion coefficient.
5. The method for optimizing parameters of a powder laser 3D printing and forming process according to claim 4, wherein in the step of establishing the selectable parameter ranges of the plurality of process parameters and the physical properties of the material:
if the material is metal single-phase powder, the physical property of the material is the inherent physical property of the metal single phase;
6. The method for optimizing parameters of a powder laser 3D printing modeling process of claim 1, wherein the step of converting the plurality of discrete process parameter values to the plurality of calculated operating conditions and the plurality of heat source loads is preceded by the step of:
determining the type of the element adopted by finite element calculation according to the material and the molding process parameters;
wherein the cell type is a cell type containing displacement and temperature degrees of freedom.
7. The method for optimizing parameters of a powder laser 3D printing and forming process of claim 1, wherein in the step of converting a plurality of discrete process parameter values into a plurality of calculation conditions and a plurality of heat source loads, the heat source loads are calculated according to a formulaCalculated, wherein Q is laser power, eta is absorption coefficient of the powder to the laser, r0Is the spot radius and r is the distance from the point to the center of the laser spot.
8. The parameter optimization method for the powder laser 3D printing forming process according to claim 1, wherein the step of obtaining a stress field calculation model and a strain field calculation model of the formed part under each discrete process parameter value further comprises:
reading a plurality of temperature data in the temperature field calculation model;
setting the elastic modulus and the yield strength value of the unformed powder by taking the plurality of temperature data as the load of stress calculation, and applying the calculation working condition;
a plurality of stress data are obtained by adopting a Newton-Raphson method in mathematics;
obtaining a stress field calculation model of the molded part through a plurality of stress data;
and obtaining a stress field calculation model of the formed part under each discrete process parameter value.
9. The method for optimizing parameters of a powder laser 3D printing molding process according to claim 8, wherein the step of obtaining a stress field calculation model of the molded part at each discrete process parameter value further comprises:
converting the plurality of stress data into a plurality of strain data;
obtaining a strain field calculation model of the formed part through a plurality of strain data;
and obtaining a strain field calculation model of the formed part under each discrete process parameter value.
10. The method for optimizing parameters of the powder laser 3D printing and forming process according to claim 8, wherein in the step of reading a plurality of temperature data in the temperature field calculation model, the temperature data comprises a depth of a molten pool, a width of the molten pool, a maximum temperature, a change of the temperature field with time in the part forming process and a solidification process of the molten pool.
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US20220270236A1 (en) * | 2019-07-25 | 2022-08-25 | Siemens Industry Software Inc. | Image-based defect detections in additive manufacturing |
CN110472355B (en) * | 2019-08-20 | 2021-09-07 | 南京航空航天大学 | 3D printing preview method based on multi-field coupling modeling and simulation solving |
CN113118458B (en) * | 2021-04-20 | 2023-04-07 | 江西省科学院应用物理研究所 | Prediction method for tensile property of metal component formed by selective laser melting |
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