CN108717481B - Prediction method for temperature distribution and warping deformation in selective laser melting process - Google Patents
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Abstract
The invention discloses a method for predicting temperature distribution and warping deformation in a selective laser melting process. The thermal analysis comprises the following steps: step1, determining processing parameters and carrying out process planning; step2, obtaining the heat correlation attribute of the metal material and establishing a model according to the size of the SLM component; step3, loading temperature boundary conditions; step4, analyzing the temperature field of the SLM component in a transient state. The mechanical analysis comprises the following steps: step5, modifying the model according to the mechanical property of the material; step6, the stress field and deformation of the member were analyzed by adding the boundary condition and using the temperature field analyzed in Step4 as the load. According to the invention, through thermosetting coupling, thermal analysis and mechanical analysis are combined, a temperature and deformation prediction system is established, and technical support is provided for optimizing process parameters and reducing warping deformation of the SLM component.
Description
Technical Field
The invention relates to the technical field of advanced manufacturing, in particular to a temperature distribution and warping deformation prediction method in a selective laser melting process.
Background
SLM (Selective laser melting) is an additive manufacturing technique that uses metal powder that is completely melted by the heat of a laser beam and is solidified by cooling to be formed. The working principle is that the laser is horizontally controlled to act on the metal powder on the surface layer according to a certain motion track, after one layer of scanning is finished, the base body descends by one layer thickness, the powder spreading system uniformly spreads the metal powder on the processed solidified layer, and the processing process is repeated until the required metal component is obtained. This unique feature makes it possible to process complex parts without expensive forming tools and complex processes, making laser additive manufacturing technology a research hotspot in engineering and manufacturing disciplines, which has been recognized by the U.S. national science foundation, the committee of the national science foundation of china as a major innovation in the 21 st century manufacturing technology.
However, the SLM process includes a moving heat source and melting and solidifying of metal, resulting in different heating and cooling rates in each region, which in turn generates residual stress in the component and causes the component to deform and even crack, resulting in failure of the component. In order to reduce component failure, a test block is generally required to be printed for trial and error test, and more reasonable process parameters are obtained. However, this process is limited by capital and time costs and cannot predict buckling of the entire component. Meanwhile, due to the limitation of experimental means, the temperature change of the component in the heating process cannot be accurately measured, and the method is used for researching the forming process and the temperature gradient of the molten pool. The SLM component simulation system developed based on fluid-solid coupling can well reveal temperature change in the machining process, predict component warping deformation and provide technical support for optimizing process parameters and reducing component defects.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a method for predicting temperature distribution and warping deformation in a selective laser melting process, which is used for analyzing phase change of a metal material, a molten pool forming process, temperature distribution, thermal stress and warping deformation in a component manufacturing process and finally predicting the temperature distribution and the final warping deformation distribution in a component processing process.
The purpose of the invention is realized by the following technical scheme: designing a prediction method of temperature distribution and warping deformation in a selective laser melting process, wherein the method comprises the following steps;
step1, selecting SLM processing technological parameters, and compiling the technological parameters in the fluid analysis software by adopting a user-defined function method;
step2, analyzing the metal powder layer by performing a laser infiltration irradiation experiment on the metal powder to obtain the laser absorption rate and the laser infiltration coefficient of the metal powder layer, simultaneously distinguishing the properties of the metal powder and a solid/liquid material, and establishing a simulation model capable of activating units layer by layer according to the size of the SLM component;
step3, loading fixed environment temperature on the bottom of the component substrate, arranging insulation on the surfaces contacted with the metal powder, arranging surface tension on the heating surface, and determining to load a body heat source or a surface heat source according to the phase state of the heating surface;
step4, obtaining the temperature field of the SLM component through transient thermal analysis on the basis of determining the time Step size and the Step number;
step5, modifying the mechanical model of the SLM component according to the mechanical properties of the material and controlling the mechanical properties of the SLM unit by using a living and dead unit method;
and Step6, adding displacement constraint to the bottom of the SLM component mechanical model, loading the temperature field obtained in the Step4 on the mechanical analysis model, and obtaining the stress field and deformation of the component by using a finite element analysis method.
Further, in Step1, the process parameters specifically include: the laser type, the laser heat source distribution mode, the laser power, the scanning speed, the effective acting radius of the laser, the ambient temperature, the layering layer thickness, the scanning path, the scanning interval and the included angle of the scanning direction of each layer. Wherein, the laser heat source distribution mode is mainly expressed in that the laser heat source distribution mode is in Gaussian distribution in the horizontal direction, and the intensity in the effective radius can reach more than 95%.
Further, in Step2, the material properties specifically include: freezing/liquefaction temperature, latent heat, viscosity, emissivity, convection coefficient, porosity, density, thermal conductivity, and specific heat capacity, wherein density, thermal conductivity, and specific heat capacity are related to the material real-time temperature.
Further, in Step2, the mechanism for distinguishing the metal powder from the solid/liquid material property is as follows: and judging whether the SLM component is melted or not by extracting microstructure temperature data in the SLM component, comparing the microstructure temperature data with the liquefaction temperature and combining the temperature change rate, so as to endow metal powder material properties or solid/liquid material properties, wherein the ratio of the metal powder to the solid/liquid material properties is related to the porosity.
Further, in Step2, the establishing a model of the layer-by-layer activatible cells according to the SLM dimension includes the following steps: and establishing a solid model according to the external size of the SLM component, selecting a proper unit size based on a finite volume method in combination with the requirements of layering thickness and calculation precision, carrying out grid division on the unit size, and activating the units layer by layer in combination with the characteristic of SLM layer-by-layer processing.
Further, in Step3, the determining, according to the phase state of the heating surface, to load a bulk heat source or a surface heat source to the heating surface includes the following steps: the change of the temperature of the heating surface micro-texture is analyzed, the heating surface micro-texture is compared with the liquefaction temperature and combined with the temperature change rate, whether the heating surface micro-texture is melted or not is judged, and because the metal powder has pores, laser generates scattering and secondary radiation in the downward irradiation process, and the heat flow density exponentially attenuates in the vertical direction, a body heat source needs to be loaded on the metal powder, the solid/liquid metal forms a compact structure, the laser cannot penetrate, the micro-structure mainly depends on heat conduction for heat transfer, and a surface heat source needs to be loaded on the solid/liquid metal.
Further, Step4 specifically includes the following steps: the method comprises the steps of determining time step length according to the ratio of grid size to laser scanning speed, determining step number according to the time required by actual working conditions, activating units in a model layer by layer, calculating a heat balance equation by using a finite volume method to obtain the temperature and heat flux density on a transient SLM member node by mainly considering the influence of member material phase state change, metal liquid convection effect and liquid metal surface tension effect on temperature distribution which are not considered by a common method by means of a CFD (computational Fluid dynamics) tool, and obtaining the temperature and heat flux density of the material phase state change, a molten pool forming process and the temperature distribution condition of the SLM member at each moment.
Further, in Step5, the mechanical properties include: density, modulus of elasticity, poisson's ratio, coefficient of thermal expansion, and yield stress, all of which are related to the real-time temperature of the material.
Further, in Step5, the controlling unit attributes by using the life and death unit method specifically includes the following steps: and judging whether the temperature of the SLM unit reaches the liquefaction temperature, gradually activating the unit by using a life and death unit method, and endowing the unit with mechanical properties.
Further, in the Step6, the Step of analyzing the stress field and deformation of the member by using the temperature field analyzed in the Step4 as the load specifically includes the following steps: and taking the temperature result obtained in the Step4 as load input, calculating a thermoelastic mechanical equilibrium formula by using a finite element analysis method to obtain stress and strain distribution conditions of each time of the SLM model, thereby obtaining residual stress, strain and buckling deformation of the SLM component in each direction, being capable of being used for researching the influence of different process parameters on the residual stress and the buckling deformation, reducing the buckling deformation by optimizing the process parameters, and developing a new scanning path because a prediction system is not constrained by a fixed scanning path, thereby reducing the buckling deformation of the SLM component.
Compared with the prior art, the invention has the following beneficial effects:
according to the invention, through thermosetting coupling, thermal analysis and mechanical analysis are combined, a temperature and deformation prediction system is established, and technical support is provided for optimizing process parameters and reducing warping deformation of the SLM component.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a schematic diagram of a method for predicting temperature distribution and warpage in a selective laser melting process;
FIG. 2 is a flow chart of an embodiment of a method for predicting temperature distribution and warp deformation during selective laser melting;
FIG. 3 is a schematic diagram of material properties imparted to SLM components in a method for predicting temperature distribution and warp distortion during selective laser melting;
FIG. 4 is a schematic diagram of a model for a method of predicting temperature distribution and warp deformation during selective laser melting;
FIG. 5 is a diagram of a distribution of SLM component temperature and distortion predicted by a method for predicting temperature distribution and warp distortion during selective laser melting.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
As shown in fig. 1 and fig. 2, the present invention provides a method for predicting temperature distribution and warpage deformation in a selective laser melting process, which is used for analyzing phase change of a metal material, a molten pool forming process, temperature distribution, thermal stress and warpage deformation in a component manufacturing process, and finally predicting temperature distribution and final warpage deformation distribution in a component processing process, and the method mainly comprises the following steps:
and Step1, selecting SLM processing technological parameters, and compiling the technological parameters in the fluid analysis software by adopting a self-defined function method. In Step1, the process parameters specifically include: the laser type, the laser heat source distribution mode, the laser power, the scanning speed, the effective acting radius of the laser, the ambient temperature, the layering layer thickness, the scanning path, the scanning interval and the included angle of the scanning direction of each layer. Wherein, the laser heat source distribution mode is mainly expressed in that the laser heat source distribution mode is in Gaussian distribution in the horizontal direction, and the intensity in the effective radius can reach more than 95%. The laser scanning path needs to be compiled, and the coordinate (x) of the laser center in the world coordinate system is obtained0,y0,z0) Is defined as a function of time with the parameters of scanning speed, scanning distance and layered thickness. When planning, defining macro function, extracting position horizontal coordinate (x) of each node or unit center of SLM componente,ye,ze) So that the coordinates of each unit or node with respect to the laser center can be obtained as (x)e-x0,ye-y0,ze-z0) So that the level of each unit with respect to the laser center can be obtainedDistance reAnd a longitudinal depth heFor reThe unit smaller than the effective radius of the laser applies a corresponding bulk heat source or a surface heat source.
And Step2, analyzing the metal powder layer by performing a laser infiltration irradiation experiment on the metal powder to obtain the laser absorptivity and laser infiltration coefficient of the metal powder layer, distinguishing the properties of the metal powder and the solid/liquid material, and establishing a simulation model capable of activating the units layer by layer according to the size of the SLM component. In Step2, the material properties specifically include: freezing/liquefaction temperature, latent heat, viscosity, emissivity, convection coefficient, porosity, density, thermal conductivity, and specific heat capacity, wherein density, thermal conductivity, and specific heat capacity are related to the material real-time temperature. As shown in fig. 3, the mechanism for distinguishing the metal powder from the solid/liquid material property is: judging whether the SLM component is melted or not by extracting microstructure temperature data in the SLM component, comparing the microstructure temperature data with the liquefaction temperature and combining the temperature change rate, so as to endow metal powder material properties or solid/liquid material properties; it is known that the ratio of the specific heat capacity and density of the metal powder to the solid/liquid state is (1-K) and the ratio of the metal powder to the solid/liquid state thermal conductivity is (1-K)/(1+ 11K) when the porosity is K2) It can be seen that the ratio of metal powder to solid/liquid material properties is related to porosity. Establishing a model of the layer-by-layer activatable unit according to the size of the SLM member, specifically comprising the steps of: as shown in fig. 4, a solid model is established according to the external dimensions of the SLM components, and based on a finite volume method in combination with the requirements of the layered thickness and the calculation accuracy, a proper unit dimension is selected and subjected to mesh division, in order to reduce the calculation amount, fine mesh division is adopted for the upper part of the substrate greatly affected by the temperature, a larger unit is given to the lower part, and the unit is activated layer by layer in combination with the characteristic of SLM layer-by-layer processing.
Step3, loading a constant ambient temperature on the bottom of the member substrate, providing insulation on the surfaces in contact with the metal powder, providing surface tension on the heating surface, and determining whether to load a body heat source or a surface heat source to the heating surface according to the phase state of the heating surface. In Step3, determining to load a bulk heat source or a surface heat source to the heating surface according to the phase state of the heating surface, specifically comprising the following steps: by analyzing the temperature change of the micro-texture of the heating surface, the method is toThe laser unit is compared with the liquefaction temperature and combined with the temperature change rate to judge whether the laser unit is melted or not, and because the metal powder has pores, the laser generates scattering and secondary radiation in the downward irradiation process, the heat flow density exponentially attenuates in the vertical direction, the metal powder needs to be loaded, and the horizontal distance r between the unit and the center of the laser unit is larger than the horizontal distance r between the unit and the center of the laser uniteAnd a longitudinal depth heRelative body heat source, solid/liquid metal forms compact structure, laser cannot penetrate, and micro structure is mainly transferred by heat conduction, so that the horizontal distance r between the solid/liquid metal surface loading and the unit relative to the laser centereAn associated surface heat source.
And Step4, obtaining the temperature field of the SLM component through transient thermal analysis on the basis of determining the time Step size and the Step number. Step4 specifically comprises the following steps: determining time step length by the ratio of grid size to laser scanning speed, determining step number according to the time required by actual working conditions, activating units in the model layer by layer, calculating a heat balance equation by using a finite volume method to obtain the temperature (shown in figure 5) and the heat flow density on a transient SLM member node by mainly considering the influence of the phase state change of a member material, the convection effect of molten metal and the surface tension effect of liquid metal on temperature distribution, which are not considered by a common method, and calculating the heat balance equation by using a finite volume method, so that the material phase state change, the molten pool forming process and the temperature distribution condition of the SLM member at each moment are obtained, the influence of different process parameters on the maximum temperature, the temperature gradient and the cooling speed can be used for researching the influence of the different process parameters on the maximum temperature, the temperature gradient and the cooling speed, and the maximum temperature can be reduced by optimizing the process parameters, and the reasonable generation rate and the temperature gradient can be obtained.
And Step5, modifying the SLM component mechanical model according to the material mechanical properties and controlling the SLM unit mechanical properties by using a living and dead unit method. In Step5, the mechanical properties include: the density, elastic modulus, poisson's ratio, coefficient of thermal expansion and yield stress, all of which are related to the real-time temperature of the material. The method for controlling the unit attribute by using the life and death unit method specifically comprises the following steps: reading the temperature field file to obtain the nodes with the temperature higher than the liquefaction temperature in each calculation step, constructing a group through a user-defined program, and utilizing life and death in a mechanical analysis modelActivating units step by a unit method; since the material properties cannot be changed during the calculation and must be greater than 0, the material properties can only be multiplied by a factor K, which is varied to control the cell properties, K being 1 for activated cells and K being 10 for inactivated cells-6。
And Step6, adding displacement constraint to the bottom of the SLM component mechanical model, loading the temperature field obtained in the Step4 on the mechanical analysis model, and obtaining the stress field and deformation of the component by using a finite element analysis method. In Step6, the temperature field obtained by analyzing in Step4 is used as a load, and the stress field and deformation of the member are obtained by analyzing, and the method specifically comprises the following steps: the temperature result obtained in the Step4 is used as load input, a finite element analysis method is used for calculating a thermoelastic mechanical equilibrium formula to obtain stress and strain distribution conditions (shown in fig. 5) of the SLM model at each moment, so that residual stress, strain and buckling deformation of the SLM component in each direction are obtained, the influence of different process parameters on the residual stress and the buckling deformation can be researched, the buckling deformation is reduced by optimizing the process parameters, and meanwhile, because a prediction system is not constrained by a fixed scanning path, a new scanning path can be developed, so that the buckling deformation of the SLM component is reduced.
While the present invention has been described with reference to the particular embodiments illustrated in the drawings, which are meant to be illustrative only and not limiting, it will be apparent to those of ordinary skill in the art in light of the teachings of the present invention that numerous modifications can be made without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (9)
1. A method for predicting temperature distribution and warping deformation in a selective laser melting process is characterized by comprising the following steps:
step1, selecting SLM processing technological parameters, and compiling the technological parameters in the fluid analysis software by adopting a user-defined function method;
step2, analyzing the metal powder layer by performing a laser infiltration irradiation experiment on the metal powder to obtain the laser absorption rate and the laser infiltration coefficient of the metal powder layer, simultaneously distinguishing the properties of the metal powder and a solid/liquid material, and establishing a simulation model capable of activating units layer by layer according to the size of the SLM component;
step3, loading fixed environment temperature on the bottom of the component substrate, arranging insulation on the surfaces contacted with the metal powder, arranging surface tension on the heating surface, and determining to load a body heat source or a surface heat source according to the phase state of the heating surface;
step4, obtaining the temperature field of the SLM component through transient thermal analysis on the basis of determining the time Step size and the Step number;
step5, modifying the mechanical model of the SLM component according to the mechanical properties of the material and controlling the mechanical properties of the SLM unit by using a living and dead unit method;
step6, adding displacement constraint to the bottom of the SLM component mechanical model, loading the temperature field obtained in the Step4 on the mechanical analysis model, and obtaining the stress field and deformation of the component by using a finite element analysis method;
the Step4 specifically includes the following steps: determining time step length according to the ratio of grid size to laser scanning speed, determining step number according to the time required by actual working conditions, activating units in the model layer by layer, calculating a heat balance equation by using a finite volume method to obtain the temperature and heat flux density on the transient SLM component node by considering the influence of component material phase state change, metal liquid convection effect and liquid metal surface tension effect on temperature distribution under a molten state by means of a CFD tool, and analyzing the material phase state change, a molten pool forming process and the temperature distribution condition of the SLM component at each moment.
2. The method of claim 1, wherein the method comprises the steps of: in Step1, the process parameters specifically include: the laser type, the laser heat source distribution mode, the laser power, the scanning speed, the effective acting radius of the laser, the ambient temperature, the layering layer thickness, the scanning direction, the scanning length, the scanning interval and the included angle of the scanning direction of each layer.
3. The method of claim 1, wherein the method comprises the steps of: in Step2, the material properties specifically include: freezing/liquefaction temperature, latent heat, viscosity, emissivity, convection coefficient, porosity, density, thermal conductivity, and specific heat capacity, wherein density, thermal conductivity, and specific heat capacity are related to the material real-time temperature.
4. The method of claim 3, wherein the method comprises the steps of: in Step2, the mechanism for distinguishing the metal powder from the solid/liquid material property is as follows: and judging the phase state of the microstructure of the SLM component at the moment by analyzing the temperature history of the microstructure of the SLM component, thereby endowing the metal powder with material properties or solid/liquid material properties, wherein the ratio of the metal powder to the solid/liquid material properties is related to the porosity.
5. The method of claim 4, wherein the method comprises the steps of: in Step2, the establishing a simulation model of the layer-by-layer activatible unit according to the SLM member size specifically includes the following steps: and establishing a solid model according to the size of the SLM component, carrying out grid division on the solid model based on a finite volume method in combination with the requirements of layering thickness and calculation precision, and activating the units layer by layer in combination with the characteristic of SLM layer-by-layer processing.
6. The method of claim 1, wherein the method comprises the steps of: in Step3, the determining, according to the phase state of the heating surface, to load a bulk heat source or a surface heat source to the heating surface includes the following steps: and analyzing the temperature change of each particle on the heating surface, judging whether the surface of the heating surface has phase change, loading a body heat source on the metal powder part, and loading a surface heat source on the solid/liquid metal surface layer.
7. The method of claim 1, wherein the method comprises the steps of: in Step5, the mechanical properties include: density, modulus of elasticity, poisson's ratio, coefficient of thermal expansion, and yield stress, all of which are related to the real-time temperature of the material.
8. The method of claim 7, wherein the step of predicting the temperature distribution and warpage deformation comprises: in Step5, the method for controlling the mechanical property of the SLM unit by using the life and death unit method specifically includes the following steps: and judging whether the temperature of the SLM unit reaches the liquefaction temperature, gradually activating the unit by using a life and death unit method, and endowing the unit with mechanical properties.
9. The method of claim 1, wherein the method comprises the steps of: in the Step6, the Step of loading the temperature field obtained in the Step4 on the mechanical analysis model and obtaining the stress field and deformation of the component by using a finite element analysis method specifically comprises the following steps: and (4) taking the temperature result obtained in the Step4 as load input, and calculating a thermoelastic mechanical equilibrium formula by using a finite element analysis method to obtain stress and strain distribution conditions of the SLM model at each time, so as to obtain residual stress, strain and buckling deformation of the SLM component in each direction.
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