CN110348072B - Method for improving finite element numerical calculation efficiency of thermal analysis of arc additive component - Google Patents
Method for improving finite element numerical calculation efficiency of thermal analysis of arc additive component Download PDFInfo
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Abstract
The invention discloses a method for improving the finite element numerical calculation efficiency of thermal analysis of an electric arc additive component, and provides a new process of 'model segmentation-iterative computation', wherein a full-size model of a large-scale component is segmented into a plurality of submodels according to structural characteristics and a forming process, the thermal analysis computation result of the submodel n-1 is used as the initial condition of n thermal analysis of the submodel, and is sequentially subjected to iterative computation, so that the negative effects of a large number of 'dead' units in a deposition area at the early stage of computation are reduced, meanwhile, the thermal analysis and the structural analysis are almost simultaneously performed in real time, the structural analysis of the full-size model can be started when the thermal analysis of the submodel 1 is finished, so that the thermodynamic indirect coupling computation has the characteristic of 'parallel computation', and the calculation efficiency is remarkably improved. The method can be widely used for predicting the distribution of the heat-force field of the large-size electric arc additive component, and has a good promotion effect on the popularization and application of finite element numerical calculation in engineering.
Description
[ technical field ] A method for producing a semiconductor device
The invention belongs to the technical field of additive manufacturing, and particularly relates to a method for improving the finite element numerical calculation efficiency of thermal analysis of an arc additive component.
[ background of the invention ]
An Additive Manufacturing (AM) technology is a novel Manufacturing technology that directly manufactures a digital model into a solid part by adopting a method of accumulating materials layer by layer based on a layered Manufacturing principle. Compared with the traditional manufacturing technology, the additive manufacturing technology has a series of advantages of high flexibility, no mold, short period, no limitation of part structures and materials and the like, and is widely applied to the fields of aerospace, automobiles, electronics, medical treatment, military industry and the like.
The Wire and Arc Additive Manufacturing (WAAM) technology adopts electric arcs as heat sources, metal parts are stacked layer by layer along a forming track according to a digital model of a target component by continuously melting filling Wire materials, and the method has the advantages of large forming size, low equipment cost, high material utilization rate, high deposition efficiency and the like, and is a method capable of realizing economic and rapid forming of high-performance metal parts.
The WAAM process has the advantages that the large-size component can be efficiently and quickly manufactured, but the stress deformation rule of the large-size component in the arc fuse deposition forming process is complex, and the finite element numerical calculation is a very effective method for analyzing and predicting deformation and stress. All units are preset before deposition is started, a live-dead unit technology is adopted to realize gradual deposition of metal, and a prediction result with high precision can be provided for additive stress deformation calculation of large complex components. The WAAM process can be similar to multilayer and multi-pass welding, and mostly adopts a thermodynamic indirect coupling calculation method, namely the node temperature obtained by thermal analysis is applied to subsequent stress analysis as a load to realize coupling calculation. However, the WAAM process is large in size (up to m magnitude) of a formed member, the instantaneous heating area of a welding heat source is relatively very small (mm magnitude), the number of required grids and the number of load steps are very large in order to ensure that the rule of a calculation result meets the actual requirement and the calculation precision meets the expected requirement, and the application and popularization of the method in engineering are not facilitated due to the fact that a conventional heat-force indirect coupling numerical analysis scheme needs very large time overhead.
In WAAM forms comprising two parts, a substrate and a deposition zone, the three-dimensional size of the substrate used in large structures is much smaller than the deposition zone, resulting in a very high proportion of the number of deposition zone cells in the full-scale model. Only a small number of units in a deposition area are activated to realize deposition of metal in the early stage of thermal-mechanical calculation, most units in the deposition area are in a dead state, but the dead units still participate in the calculation process, the difficulty and time for solving a temperature matrix in thermal analysis are increased, and the calculation amount is obviously increased. According to past experience, solutions for low computational efficiency include sedimentary layer merging, intralayer load step merging, simplification of a heat source model, reduction of the number of meshes and the like. However, in order to ensure the accuracy of the calculation, the combination and reduction have certain limitations, and the oversimplification can cause the convergence and the accuracy of the calculation to be greatly deteriorated. Meanwhile, the characteristics of large number of grids in the deposition area and extremely large occupation ratio cannot be effectively changed by adopting any method, so that the calculation efficiency is difficult to greatly improve.
[ summary of the invention ]
The invention aims to overcome the defects of the prior art and provides a method for improving the finite element numerical calculation efficiency of the thermal analysis of an arc additive component. The numerical calculation method provides a new flow of 'model segmentation-iterative calculation', reduces the number of 'dead' units in a deposition area at the early stage of calculation, and accordingly improves the calculation efficiency of thermal analysis at the early stage and structural analysis.
In order to achieve the purpose, the invention adopts the following technical scheme to realize the purpose:
a method for improving the efficiency of finite element numerical calculation of thermal analysis of an arc additive component comprises the following steps:
(1) according to a structural design drawing of a target forming component, establishing a full-size solid model of a deposition piece and a substrate, and dividing the full-size solid model into grids to obtain the full-size solid model after the grids are divided, wherein the divided grids have l layers, and l is a natural number more than or equal to 1;
(2) obtaining n submodels in total according to the number l of layers of grid division in the full-size solid model; the submodel k is a deposition area for adding m layers on the submodel k-1, wherein m is more than or equal to 1 and less than l, n is more than or equal to 1 and less than or equal to l, and k is more than 1 and less than or equal to n;
(3) performing thermal analysis calculation on the submodel 1, and starting structural analysis settlement on the full-size model when the thermal analysis calculation of the submodel 1 is finished; the initial condition of the kth sub-model thermal analysis calculation is the result of the kth-1 sub-model thermal analysis calculation; and simultaneously carrying out thermal analysis calculation on each submodel in sequence, synchronously carrying out structural analysis calculation on the full-size model, and finally ending the thermal analysis calculation of the submodel n and the structural analysis calculation of the full-size entity model.
The invention is further improved in that:
preferably, in step (2), 1. ltoreq. m.ltoreq.5.
Preferably, in step (2), n is l and m is 1.
Preferably, in step (2), the nodes at the same spatial position in the n submodels and the full-size solid model are numbered the same.
Preferably, the specific process of step (3) is: when the thermal analysis calculation of the sub-model 1 is finished, applying the temperature field calculation result of the sub-model 1 as a temperature load to the same position of the full-size model, performing structural analysis calculation corresponding to the sub-model 1, and simultaneously starting the thermal analysis calculation of the sub-model 2, wherein the initial condition of the thermal analysis calculation of the sub-model 2 is the result of the thermal analysis calculation of the sub-model 1;
when the thermal analysis of the sub-model 2 is finished, taking the structural analysis result corresponding to the sub-model 1 as an initial condition, gradually applying the thermal analysis calculation result of the sub-model 2 to the same position corresponding to the sub-model 2 on the full-size model along with the time according to the deposition process, and carrying out structural analysis calculation corresponding to the sub-model 2; and analogizing in sequence to the sub-model k and to the sub-model n, wherein the structural analysis corresponding to the sub-model n on the full-size model takes the structural analysis result corresponding to the sub-model n-1 as an initial condition, the thermal analysis calculation result of the sub-model n is gradually applied to the same position corresponding to the sub-model n on the full-size model along with the time according to the deposition process, and after the structural analysis calculation corresponding to the sub-model n on the full-size model is finished, the structural analysis calculation of the full-size entity model is finished.
Preferably, in the step (3), the heat source model of the thermal analysis calculation is a moving temperature heat source.
Preferably, in the step (3), the thermal analysis process of the submodel k is a heating process for increasing the deposition area of the m layers compared with the submodel k-1.
Preferably, the stress deformation condition of the deposition process is obtained by using a thermodynamic indirect coupling method in the step (3).
Preferably, in step (3), the m-layer deposition area increased in the submodel k compared with the submodel k-1 is a dead area before the thermal analysis calculation of the submodel k.
Preferably, the arc additive method of the target shaped component includes metal inert gas welding, non-metal inert gas welding, plasma arc welding and cold metal transfer welding.
Compared with the prior art, the invention has the following beneficial effects:
the invention discloses a method for improving the finite element numerical calculation efficiency of thermal analysis of an electric arc additive component, which is characterized in that a full-size model is divided relative to the conventional heat/force indirect coupling calculation process, a model division-iterative calculation method is adopted, units of a substrate and a current m-layer deposition area are only included in a sub-model participating in the calculation early stage, a large number of units of the remaining deposition area to be deposited are excluded from the model, the number of dead units is greatly reduced, the negative effects of dead units of the large number of deposition areas in the calculation early stage are reduced, the calculated amount is reduced, and the calculation efficiency is improved; the invention is different from the conventional method of firstly carrying out thermal calculation and then carrying out structural analysis, so that the thermal indirect coupling calculation has the characteristic of 'parallel calculation', the structural analysis does not need to wait until the thermal analysis is completely finished, the temperature field of the first sub-model can be loaded in the full-size structural model for calculation after the thermal analysis of the first sub-model is finished, the thermal analysis calculation and the structural analysis calculation are almost simultaneously carried out in the whole thermal-force indirect coupling calculation process, the higher thermal indirect coupling calculation efficiency is ensured to the maximum extent, the calculation efficiency is further improved, and the time for the thermal analysis calculation can be reduced to 50 percent of the original time.
Furthermore, the number of meshes divided by the full-size solid model is determined according to the structural characteristics of the full-size solid model and the forming method of the target forming component, so that the established model can be suitable for structural members with different shapes.
Furthermore, when any submodel carries out thermal analysis calculation, the sedimentary deposit behind the submodel is excluded from the submodel, and the calculation efficiency of thermal analysis is improved.
Further, the target forming member of the present invention can be manufactured by a conventional arc welding method, so the model is suitable for any arc additive manufacturing construction mode, and the application range is wide.
[ description of the drawings ]
FIG. 1 is a schematic view of the "model segmentation-iterative computation" flow chart in the present invention;
FIG. 2 is a time sequence Gantt chart corresponding to the thermodynamic indirect coupling calculation completed by the "model segmentation-iterative calculation" process and the conventional process respectively in the present invention;
FIG. 3 shows the results of model segmentation according to an embodiment of the present invention;
FIG. 4 is a comparison graph of the thermal analysis calculation time of the embodiment using the flow of the present invention and the conventional flow.
[ detailed description ] embodiments
The invention is described in further detail below with reference to the following figures and specific examples:
referring to fig. 1, the invention discloses a method for improving the finite element numerical calculation efficiency of thermal analysis of an arc additive component, which specifically comprises the following steps:
(1) establishing full-size solid models of a deposition part and a substrate according to a structural design drawing of a large-scale electric arc additive target forming component, and discretizing the full-size solid models through grid division to obtain the full-size solid models after grid division, wherein the grid division needs to match the structural characteristics and the forming process of a target forming part as much as possible, the structural characteristics mainly comprise structure and size, and the forming process comprises a deposition path and process parameters; the divided grids share l layers, wherein l is a natural number more than or equal to 1; the arc types of the arc additive forming component comprise consumable electrode inert gas shielded welding, non-consumable electrode inert gas shielded welding, plasma arc welding, cold metal transition welding and the like, so that the model is suitable for any arc additive manufacturing and constructing mode and has wide application range;
(2) dividing the constructed full-size model according to the structural characteristics and the forming process to obtain n submodels, wherein the submodel k is a deposition area for adding m layers on the submodel k-1, m is more than or equal to 1 and less than l, and k is more than 1 and less than or equal to n; m, n and k are natural numbers; the submodel n is a deposition area for increasing m layers on the basis of the submodel n-1, in the invention, the height of the submodel k, which is increased compared with the submodel k-1, is about within 5 times of the height of an actual single-layer deposition welding bead, namely m is preferably not less than 1 and not more than 5, and is selected according to the actual situation, more preferably, m is 1, namely the preferable scheme is that the number of layers of the segmentation grids in the full-size model is equal to the number of established submodels, and l is n; in the process of model segmentation, the node numbers of the n submodels and the nodes at the same spatial position in the full-size model are ensured to be completely consistent. The model size for which the invention is applicable can theoretically be of the order of meters, but should not be less than 300mm, otherwise the effectiveness of the method would be reduced.
(3) Carrying out thermal analysis calculation aiming at the sub-model 1, and when the thermal analysis calculation of the sub-model 1 is finished, obtaining a thermal analysis calculation result of the model 1, namely applying the thermal analysis calculation result on a full-size structural model as a temperature load, and calculating to obtain a stress deformation evolution process of a member; the time when the structural analysis starts is the time when the thermal analysis calculation of the sub-model 1 is finished, and the higher thermodynamic indirect coupling calculation efficiency can be ensured to the greatest extent.
Meanwhile, the submodel 2 starts thermal analysis calculation, and the initial condition of the submodel 2 thermal analysis calculation is the result of the submodel 1 thermal analysis calculation;
(4) and performing thermal analysis simultaneously with structural analysis, wherein the structural analysis object is a full-size model, the applied temperature load is derived from the thermal analysis calculation results of the sub-models, the starting time of the structural analysis calculation is the thermal analysis calculation end of the sub-model 1, and the thermal analysis calculation results of the sub-models 1-n are applied to the same position corresponding to each sub-model on the full-size model according to the temperature load. The specific process is as follows:
when the thermal analysis of the submodel 2 is finished, the submodel 3 starts to perform thermal analysis calculation, and so on until the submodel k … reaches the submodel n; the temperature field calculation result of the submodel (k-1) will be used as the initial condition of the submodel k thermal analysis, the thermal analysis of the submodel k is only for the gradual heating process of the m-layer deposition areas increased compared with the submodel k-1, and the m-layer deposition areas increased compared with the submodel k-1 in the submodel k are in a 'killing' state before being heated by the heat source for the first time (namely, the rigidity matrix is multiplied by a small factor, the default value is 1.0E-6) until being heated for the first time and being 'activated'); while each submodel carries out thermal analysis calculation in sequence, the structural analysis calculation of the full-size model is almost synchronously carried out, and the phase difference time is the thermal analysis calculation time of the submodel 1; if the structural analysis calculation corresponding to the sub-model 2 is carried out on the full-size solid model, taking the structural analysis result corresponding to the sub-model 1 as an initial condition, gradually applying the thermal analysis calculation result of the sub-model 2 to the same position corresponding to the sub-model 2 on the full-size solid model along with the deposition process along with the time, and carrying out the structural analysis calculation corresponding to the sub-model 2; when the structural analysis and calculation corresponding to the submodel 2 on the full-size model is finished, the structural analysis corresponding to the submodel 3 on the full-size model takes the structural analysis result corresponding to the submodel 2 as an initial condition, and the thermal analysis and calculation result of the submodel 3 is gradually applied to the same position corresponding to the submodel 3 on the full-size model along with the time according to the deposition process to perform the structural analysis and calculation corresponding to the submodel 3 on the full-size model; and after the structural analysis and calculation corresponding to the submodel 3 on the full-size model is finished, analogizing in sequence, wherein the structural analysis corresponding to the submodel n on the full-size model takes the structural analysis result corresponding to the submodel n-1 as an initial condition, the thermal analysis and calculation result of the submodel n is gradually applied to the same position corresponding to the submodel n on the full-size model along with time according to the deposition process, and after the structural analysis and calculation corresponding to the submodel n on the full-size model is finished, the structural analysis and calculation of the full-size entity model is finished.
The heat source model calculated by the thermal analysis is preferably a mobile temperature heat source; the stress deformation condition in the deposition process is obtained by adopting a thermodynamic indirect coupling method, namely the temperature of a node obtained by thermal analysis of each sub-model is applied to a corresponding position of the full-size model as a load to carry out structural analysis so as to realize thermodynamic coupling calculation.
The heat source model in the thermal analysis calculation in the above step is a moving temperature heat source.
Referring to fig. 2, a time sequence gantt chart corresponding to the indirect thermodynamic coupling calculation completed by the "model segmentation-iterative calculation" flow and the conventional flow respectively is shown, and it can be seen from the figure that the conventional flow is subjected to thermal analysis first and then structural analysis when finite element calculation is performed; the new process of 'model segmentation-iterative computation' is adopted, so that thermal analysis and structural analysis are almost simultaneously performed in real time, structural analysis can be started when the thermal analysis of the sub-model 1 is finished in the new process, the feature of thermodynamic indirect coupling 'parallel' computation is provided, the total time of thermodynamic indirect coupling computation is remarkably improved, and the time for thermal analysis computation can be reduced to 50% of the original time.
Examples
FIG. 3 shows a large size aluminum alloy thin wall member with an axial height of 1200mm and a central cylindrical region wall thickness 1/2 of 1000mm diameter. The single pass deposition pass width was about 7.5mm and the monolayer thickness was around 3mm using CMT arc fuse additive deposition formation. In mesh division, to reduce the number of meshes, the minimum cell size of the deposition zone is about 7.5 mm. The deposition zone and substrate totaled 48284 cells, 78984 nodes, with 6720 bottom square substrate cells, 9000 nodes, and approximately 11.4% nodes total.
Merging deposition layers based on structural characteristics and a forming process, setting the number of the deposition layers to be 95, setting 1 thermal analysis load step for each layer, and respectively completing three-dimensional transient thermal analysis calculation by adopting a conventional method and a new method of 'model segmentation-iterative calculation', wherein except for differences in calculation flows, other parameters such as material thermal property, boundary conditions and heat source loading parameters are kept consistent. The boundary conditions comprise thermal analysis boundary conditions and structural analysis boundary conditions, convection heat transfer and radiation are considered on all outer surfaces of the model during thermal analysis, and the structural analysis considers the constraint effects of supports and clamps in the printing process and prevents the model from generating unnecessary rigid drift and rotation. Further, the model initial temperature before the arc fuse deposition was started was room temperature (298.15K). The moving temperature heat source is adopted to simulate the moving of an electric arc, and the gradual deposition of welding wire materials is realized through the technology of presetting a deposition area unit and a live-dead unit.
Fig. 4 shows the time-varying curves calculated by the two methods as the number of deposited layers increases. As can be seen from fig. 4, when the new method is adopted, the calculation efficiency (the slope of the time-layer number curve) is very high due to the extremely small number of the units at the early stage, and the calculation speed is continuously reduced along with the increase of the number of the units, and is consistent with the conventional method when the calculation is close to the end. The total number of units in the conventional calculation method is consistent, so the difference between the calculation speed and the calculation speed is small and basically kept constant. Finally, the total time of thermal analysis calculation of the model is about 3.46h by adopting the new method, while the conventional method needs 7.38h, which saves about 53.1% totally, namely, the remarkable improvement of the calculation efficiency by the new flow of 'model segmentation-iterative calculation' is verified.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (1)
1. A method for improving the efficiency of finite element numerical calculation of thermal analysis of an arc additive component is characterized by comprising the following steps:
(1) according to the structural design drawing of the target forming component, a full-size solid model of a deposition piece and a substrate is established, the full-size solid model is divided into grids to obtain the full-size solid model after the grids are divided, and the divided grids are sharedlA layer of a material selected from the group consisting of,lis a natural number more than or equal to 1;
(2) number of layers divided according to mesh in full-size solid modellTo obtainnA sub-model; sub-modelkIs an on-sub modelk-1Upper increasemA deposition area of the layer, wherein,1≤m＜l，1≤n≤l，1＜k≤nor is orn=l，m=1；
In the step (2),nthe node numbers of the same space position in the submodel and the full-size solid model are the same;
(3) sub-model1Performing thermal analysis calculation, sub-model1When the thermal analysis calculation is finished, the full-size model starts to perform structural analysis settlement; first, thekThe initial condition for the sub-model thermal analysis calculation isk-1The result of the sub-model thermal analysis calculation; while each submodel carries out thermal analysis calculation in sequence, the structural analysis calculation of the full-size model is carried out synchronously, and finally, the submodel is obtainednThe thermal analysis calculation and the structural analysis calculation of the full-size solid model are finished;
the specific process of the step (3) is as follows: sub-model1When the thermal analysis calculation is finished, the sub-model is set1The temperature field calculation result of (2) is used as the same position of the temperature load applied to the full-size model to perform the sub-model1Corresponding structural analysis calculation, and submodel at the same time2Starting thermal analysis calculation, sub-model2The initial condition of thermal analysis calculation is a sub-model1Results of thermal analysis calculations;
in step (3), sub-modelkThe thermal analysis process of (A) is a phase contrast modelk-1Increase ofmA heating process of the layer deposition area;
in the step (3), a thermodynamic indirect coupling method is adopted to obtain the stress deformation condition in the deposition process;
in step (3), sub-modelkMiddle phase comparison submodelk-1Increased ofmLayer deposition zone in sub-modelkBefore the thermal analysis calculation, the dead zone is obtained;
sub-model2When the thermal analysis is finished, the submodel is used1Taking the corresponding structural analysis result as an initial condition, and modeling the sub-model2The thermal analysis calculation result is gradually applied to the full-size model according to the deposition process and along with the time2Corresponding to the same position, performing sub-model2Corresponding structural analysis calculation; analogizing to the submodel in turnkTo the submodelnUpper sub-model of full-scale modelnCorresponding structural analysis to submodeln-1The corresponding structural analysis result is the initial condition, and the sub-model is usednThe thermal analysis calculation result is gradually applied to the full-size model according to the deposition process and along with the timenCorresponding sub-model on the same-position full-size modelnAfter the corresponding structural analysis and calculation is finished, the structural analysis and calculation of the full-size solid model is finished;
in the step (3), a heat source model for thermal analysis calculation selects a movable temperature heat source;
arc additive methods for target shaped components include gas metal arc welding, non-gas metal arc welding, plasma arc welding, and cold metal transfer welding.
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