CN111523269A - Method for predicting temperature and warping deformation of printed matter in fused deposition manufacturing process - Google Patents
Method for predicting temperature and warping deformation of printed matter in fused deposition manufacturing process Download PDFInfo
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- CN111523269A CN111523269A CN202010332075.5A CN202010332075A CN111523269A CN 111523269 A CN111523269 A CN 111523269A CN 202010332075 A CN202010332075 A CN 202010332075A CN 111523269 A CN111523269 A CN 111523269A
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- 238000000034 method Methods 0.000 title claims abstract description 73
- 230000008021 deposition Effects 0.000 title claims abstract description 39
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 238000009826 distribution Methods 0.000 claims abstract description 38
- 230000008569 process Effects 0.000 claims abstract description 35
- 239000000463 material Substances 0.000 claims abstract description 34
- 238000007639 printing Methods 0.000 claims abstract description 28
- 238000004088 simulation Methods 0.000 claims abstract description 8
- 238000002076 thermal analysis method Methods 0.000 claims abstract description 5
- 230000001052 transient effect Effects 0.000 claims abstract description 5
- 238000000465 moulding Methods 0.000 claims description 11
- 238000006243 chemical reaction Methods 0.000 claims description 5
- 238000005516 engineering process Methods 0.000 claims description 5
- 238000006073 displacement reaction Methods 0.000 claims description 4
- 230000000977 initiatory effect Effects 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 10
- 238000012546 transfer Methods 0.000 description 6
- 238000005728 strengthening Methods 0.000 description 5
- 238000001816 cooling Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 230000005855 radiation Effects 0.000 description 4
- 230000008859 change Effects 0.000 description 3
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- 230000003213 activating effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
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- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
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- B33Y50/00—Data acquisition or data processing for additive manufacturing
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- G—PHYSICS
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- G06F2113/00—Details relating to the application field
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- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/08—Thermal analysis or thermal optimisation
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Abstract
The invention provides a method for predicting the temperature and warping deformation of a printed material in a fused deposition manufacturing process, which comprises the following steps: acquiring a simulation model of the printed piece and meshing the model; acquiring thermal property related parameters of the model; obtaining the temperature distribution of the printed piece in the fused deposition forming process by utilizing transient thermal analysis according to the gridded model and the thermal related parameters; obtaining the mechanical property of the model to obtain a mechanical model of the printed piece; and obtaining the stress distribution and deformation of the printing piece in the fused deposition forming process by taking the mechanical model and the temperature distribution of the printing piece in the fused deposition forming process as the basis. The method aims to solve the problem that the distribution of temperature and stress and the warping deformation of parts in the forming process cannot be predicted due to the limitation of capital and time cost in the center of the prior art.
Description
Technical Field
The invention relates to the field of advanced manufacturing, in particular to a method for predicting the temperature and warping deformation of a printed product in a fused deposition manufacturing process.
Background
In recent years, FDM (Fused Deposition Modeling) has been widely used due to its characteristics of low cost, easy maintenance, wide range of molding materials, low price, small occupied space, and the like. When the model is formed by the FDM technology, the adopted material is basically thermoplastic material, the material is heated at a nozzle, the molten material is extruded from the nozzle and is stacked layer by layer along with the movement of the nozzle, and then the molten material is cooled gradually, and finally the required model is formed. In the molding process, the material undergoes multiple uneven heating and cooling cycles, which causes different curing times at various positions of the model and uneven distribution of temperature field and stress field, and further causes buckling deformation, even failure phenomena such as interlayer debonding and cracking, and the molding precision is affected. In order to avoid part failure as much as possible and reduce the buckling deformation of parts, a test block is generally required to be printed before formal production for trial and error test, so that more reasonable printing parameters are obtained. However, this process is limited by capital and time costs, and by measurement means in the experiment, the distribution of temperature and stress in the molding process of the part cannot be obtained well, and the warpage deformation of the entire part cannot be predicted.
Disclosure of Invention
In view of the above-mentioned shortcomings of the prior art, the present invention at least aims to provide a method for predicting the temperature and warpage of a printed material in a fused deposition manufacturing process, which aims to solve the problem that the temperature, stress distribution and warpage of a part in a molding process cannot be predicted due to the limitation of capital and time cost in the center of the prior art.
To achieve the above and other related objects, one embodiment of the present invention provides a method for predicting temperature and warp deformation of a print in a fused deposition manufacturing process, comprising the steps of:
acquiring a simulation model of the printed piece and meshing the model;
acquiring thermal property related parameters of the model;
obtaining the temperature distribution of the printed piece in the fused deposition forming process by utilizing transient thermal analysis according to the gridded model and the thermal related parameters;
obtaining the mechanical property of the model to obtain a mechanical model of the printed piece;
and obtaining the stress distribution and deformation of the printing piece in the fused deposition forming process by taking the mechanical model and the temperature distribution of the printing piece in the fused deposition forming process as the basis.
In one embodiment, the step of obtaining the model and meshing the model comprises:
establishing a simulation model according to the shape and the size of a part to be printed;
and defining the printing line width as the length and width of the cell, defining the layering layer thickness as the height of the cell, and performing grid division on the model.
In one embodiment, the thermal property-related parameters include: at least one of a cell type, a thermophysical parameter of the print material, a thermal property initiation condition of the fused deposition fabrication apparatus, a thermal property boundary condition of the print, a scan mode, a load-load mode, and a load step.
In one embodiment, the thermophysical parameters include: at least one of density, specific heat capacity, heat conductivity coefficient and comprehensive heat exchange coefficient.
In one embodiment, the step of basing the gridded model and the thermally related parameters comprises:
defining the thermophysical property parameter;
setting initial conditions, boundary conditions, a load loading mode and a load step;
and determining a scanning mode based on the living and dead unit technology, the set load loading mode and the load step.
In one embodiment, the load loading mode is a step mode loading.
In one embodiment, the step size of the load step is a dynamic step size, and is set according to the printing speed and the cell length.
In one embodiment, the step of obtaining mechanical properties of the model comprises:
performing unit type conversion;
defining mechanical properties of the material after the unit type conversion, wherein the mechanical properties comprise: at least one of elastic modulus, Poisson's ratio, coefficient of thermal expansion, tensile yield stress.
In one embodiment, the step of obtaining the stress distribution and deformation of the printed material during the fused deposition modeling process based on the mechanical model and the temperature distribution of the printed material during the fused deposition modeling process comprises:
adding displacement constraint at the bottom of the mechanical model;
loading the node temperature as a volume load onto a corresponding node according to the temperature distribution of the printed matter in the fused deposition molding process;
and solving by using a finite element method to obtain the stress distribution and deformation of the printed piece in the fused deposition forming process.
In one embodiment, the step of loading the node temperatures as a bulk load onto the respective nodes according to the temperature distribution of the print during the fused deposition modeling includes:
reading a result file of the temperature distribution of the printing piece in the fused deposition forming process through the reading command;
and loading the node temperature as a body load on the corresponding node.
According to the technical scheme provided by the embodiment of the invention, the part is subjected to heat-force coupling calculation in the fused deposition forming process by using ANSYS, so that the temperature distribution, the stress distribution and the deformation of the model in the fused deposition manufacturing process can be obtained through one-time calculation, and the temperature distribution and the final warping deformation in the part forming process are predicted; technical support is provided for optimizing printing parameters and reducing defects of printed products.
Drawings
FIG. 1 shows a schematic diagram of a method according to the invention;
FIG. 2 is a flow chart showing an embodiment of the method of the present invention;
FIG. 3 is a graph showing the results of model meshing;
FIG. 4 is a schematic view of a scanning mode;
FIG. 5a is a graph showing the deformation profile of a part just printed and formed using the method of the present invention;
FIG. 5b is a graph showing the temperature profile of a part just after printing and forming, measured by the method of the present invention;
FIG. 6a is a graph showing the distortion profile of a part after cooling for 20s, measured using the method of the present invention;
FIG. 6b shows the temperature profile of a part cooled for 20s using the method of the present invention.
Description of the element reference numerals
| Reference numerals | Name (R) |
| 1 | Rectangular |
| 11 | |
| 12 | |
| 13 | Third layer |
Detailed Description
The following description of the embodiments of the present invention is provided for illustrative purposes, and other advantages and effects of the present invention will become apparent to those skilled in the art from the present disclosure.
Referring to fig. 1 and 2, fig. 1 is a schematic diagram of a method for predicting temperature and warp deformation of a printed product during a fused deposition manufacturing process, which is based on an APDL language and is used to analyze temperature distribution, stress distribution and warp deformation of a part during a fused deposition molding process, and finally predict the temperature distribution and the final warp deformation during the part printing process, so as to provide technical support for optimizing printing parameters and reducing warp deformation generated by printing the part by using an FDM technique. Fig. 2 is a flow chart of a specific implementation of the method of the present invention, which mainly includes the following steps:
step S1: defining unit types, and defining the thermophysical property parameters of the material according to the material adopted in printing; in the first step, the unit type is selected from SOLID70 three-dimensional thermal entity units which are suitable for transient or steady state thermal analysis and have life-death capability. The thermophysical parameters of the material comprise: density, specific heat capacity, thermal conductivity, and comprehensive heat transfer coefficient, all of which are related to the real-time temperature of the material. The comprehensive heat transfer coefficient is obtained by comprehensively considering heat convection and heat radiation, and the expression of the comprehensive heat transfer coefficient h is as follows:
h＝σ(Tp 2+Tc 2)(Tp+Tc)+hc
wherein the value of the sigma-Stefan-Boltzmann constant is 5.67 × 10-8W/m2·K4；
-material blackness;
Tp-the part temperature;
Tc-ambient temperature;
hc-natural convective heat transfer coefficient.
The density, specific heat capacity and heat conductivity coefficient are defined by adopting 'MPTEMP' and 'MPDATA' commands, and the comprehensive heat exchange coefficient is defined by adopting an array form.
Step S2: establishing a simulation model of a printed part according to the shape and the size of a part to be printed and carrying out grid division; in the second step, a simulation model is established according to the shape and the size of the part to be printed and is subjected to grid division, and the method specifically comprises the following steps:
the first step is as follows: establishing a simulation model according to the shape and size of the part to be printed;
referring to fig. 3, fig. 3 is a diagram showing a result of model meshing, and as shown in fig. 3, the invention uses a rectangular parallelepiped model 1 as an example to perform meshing.
The second step is that: based on a finite volume method, combining the layering thickness and the printing line width, defining the printing line width as the length and the width of a cell, defining the layering layer thickness as the height of the cell, and carrying out grid division.
Step S3: setting initial conditions and boundary conditions; in the third step, the initial condition is the temperature at the beginning of printing, and since the machine is preheated according to the temperature set by the user before printing by FDM, the initial temperature is known and includes the nozzle temperature, the molding chamber temperature, and the bottom plate temperature. The boundary conditions are that the formed materials are subjected to heat transfer through heat conduction, the formed materials and air in the forming chamber are subjected to heat transfer through heat convection and heat radiation, phase change exists in the process that the materials are gradually cooled from a molten state to a solid state, phase change latent heat also exists, and the material is treated by adopting a specific heat capacity mutation method, namely the function of replacing the latent heat by the mutation of the specific heat capacity of a substance. In ANSYS, latent heat is taken into account by the enthalpy of the material, and the specific enthalpy is expressed in KJ/Kg and is calculated by the following formula:
H＝∫ρc(T)dT
in the formula (I), the compound is shown in the specification,
h-enthalpy;
ρ is the material density;
c (T) -function of the specific heat capacity of the material as a function of temperature.
Step S4: according to the selected scanning mode, life or death is utilizedThe unit technology obtains the temperature distribution of the part in the fused deposition molding process through transient thermal analysis according to a set load loading mode and load steps; in the fourth step, the living and dead unit technology refers to that if materials are added or deleted from the model, the corresponding units in the model exist or disappear. The "death" of a cell is not removed from the model, but rather its stiffness matrix or conductance matrix or other characteristic matrix is associated with a small factor [ ESTIF]Multiplication, the factor defaults to 1.0e-6Setting the unit load, the mass, the rigidity, the specific heat and the like to be 0, excluding the mass and the energy of a dead unit from the solving result of the model, and setting the strain of the unit to be 0 while killing; the 'birth' of the unit is not to add a new unit in the model, but to reactivate the unit, and the rigidity, the mass, the unit load and the like of the unit can restore the original values after the unit is activated. The load loading mode comprises a slope application mode and a step application mode in ANSYS. In the process of printing a part by using FDM, the distance between a nozzle and a printing plane is short, the extruding speed of the wire is high, so that the time from the nozzle to a molding surface of the wire is short, the heat dissipation of the material in the process is negligible, and the load is loaded in a step mode. The step length of the load step is set according to the printing speed and the length of the cell, and a dynamic step length is adopted.
Referring to fig. 4, fig. 4 is a schematic view illustrating a scanning method. As shown in fig. 4, the invention takes the parallel reciprocal scanning along the axis X, Y as an example, the rectangular parallelepiped model 1 is divided into a first layer 11, a second layer 12, and a third layer 13, and the specific scanning route is the marked line with direction in the figure.
Further, the specific steps of the fourth step are as follows:
the first step is as follows: ALL finite element elements are "killed" by the "EKILL, ALL" command;
the second step is that: sequentially activating the Nth unit through an 'EALIVE' command according to a set path;
the third step: sequentially applying temperature load and convection radiation conditions on the Nth unit node;
the fourth step: setting a load loading mode, a load step length and a load sub-step;
the fifth step: solving and deleting the temperature load of the Nth unit node;
and a sixth step: judging whether all the finite element units are activated or not, if the finite element units which are not activated exist, returning to the second step, and continuing to circulate until all the finite element units are activated;
the seventh step: entering a cooling stage after printing is finished, selecting a surface unit of the model, and reapplying convection radiation conditions;
eighth step: setting cooling time, and solving according to the same load step length and load sub-step;
the ninth step: and performing post-treatment to obtain the temperature distribution of the part at each moment in the fused deposition forming process, thereby obtaining the relevant information of the temperature gradient.
Step S5: converting the unit type, and defining the mechanical property of the material; in the fifth step, the conversion unit type is to convert SOLID70 into SOLID 185. The mechanical properties of the material comprise: modulus of elasticity, poisson's ratio, coefficient of thermal expansion, tensile yield stress, all of which are related to the material's real-time temperature. The "MPTEMP" and "MPDATA" commands are used to define the elastic modulus, poisson's ratio, and coefficient of thermal expansion. The elastic-plastic theory strengthening model is divided into a bilinear equidirectional strengthening model, a multilinear equidirectional strengthening model and a nonlinear equidirectional strengthening model, and an appropriate strengthening model is selected according to the characteristics of materials when the tensile yield stress is defined.
Step S6: adding displacement constraint at the bottom of the part mechanical model, loading the 'rth' file obtained in the fourth step, loading the node temperature as a body load to a corresponding node, and solving by a finite element method to obtain the stress distribution and deformation of the part in the fused deposition molding process. The sixth step comprises the following specific steps:
the first step is as follows: applying a displacement constraint condition at the bottom of the model; the invention is exemplified by a bottom total constraint.
The second step is that: reading the ". rth" file obtained in the fourth step through an "LDREAD" command, and loading the node temperature as a body load onto the corresponding node.
The third step: and setting the load loading mode as a step mode, setting the load step length to be the same as the load step length in the step four, and setting the load sub-step.
The fourth step: and entering a post-processing stage to obtain the stress distribution of the part at each moment in the fused deposition forming process so as to obtain the buckling deformation condition.
Referring to fig. 5a, fig. 5b, fig. 6a and fig. 6b, wherein fig. 5a is a distribution diagram of deformation of a part just printed and formed according to the method of the present invention; FIG. 5b is a graph of the temperature profile of a part just after printing and forming, measured using the method of the present invention; FIG. 6a is a graph of the distortion profile of a part as it is cooled for 20s using the method of the present invention; FIG. 6b is a graph of the temperature profile of a part cooled for 20s using the method of the present invention. From the above figures, the method of the present invention can accurately obtain the temperature distribution and the deformation distribution map of the printed material.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
Claims (10)
1. A method for predicting the temperature and warp deformation of a printed material in a fused deposition manufacturing process is characterized by comprising the following steps:
acquiring a simulation model of the printed piece and meshing the model;
acquiring thermal property related parameters of the model;
obtaining the temperature distribution of the printed piece in the fused deposition forming process by utilizing transient thermal analysis according to the gridded model and the thermal related parameters;
obtaining the mechanical property of the model to obtain a mechanical model of the printed piece;
and obtaining the stress distribution and deformation of the printing piece in the fused deposition forming process by taking the mechanical model and the temperature distribution of the printing piece in the fused deposition forming process as the basis.
2. The method of claim 1, wherein the step of obtaining the model and meshing the model comprises:
establishing a simulation model according to the shape and the size of a part to be printed;
and defining the printing line width as the length and width of the cell, defining the layering layer thickness as the height of the cell, and performing grid division on the model.
3. The method of claim 1, wherein the thermal property-related parameters include: at least one of a cell type, a thermophysical parameter of the print material, a thermal property initiation condition of the fused deposition fabrication apparatus, a thermal property boundary condition of the print, a scan mode, a load-load mode, and a load step.
4. The method of claim 3, wherein the thermal property parameters comprise: at least one of density, specific heat capacity, heat conductivity coefficient and comprehensive heat exchange coefficient.
5. The method of claim 3, wherein the step of basing the gridded model and the thermal related parameters comprises:
defining the thermophysical property parameter;
setting initial conditions, boundary conditions, a load loading mode and a load step;
and determining a scanning mode based on the living and dead unit technology, the set load loading mode and the load step.
6. The method of claim 5, wherein the load is applied in a step-wise manner.
7. The method of claim 5 or 6, wherein the step size of the loading step is a dynamic step size and is set according to the printing speed and the cell length.
8. The method of claim 1, wherein the step of obtaining the mechanical properties of the model comprises:
performing unit type conversion;
defining mechanical properties of the material after the unit type conversion, wherein the mechanical properties comprise: at least one of elastic modulus, Poisson's ratio, coefficient of thermal expansion, tensile yield stress.
9. The method according to claim 1, wherein the step of obtaining the stress distribution and deformation of the printed material during the fused deposition modeling process based on the mechanical model and the temperature distribution of the printed material during the fused deposition modeling process comprises:
adding displacement constraint at the bottom of the mechanical model;
loading the node temperature as a volume load onto a corresponding node according to the temperature distribution of the printed matter in the fused deposition molding process;
and solving by using a finite element method to obtain the stress distribution and deformation of the printed piece in the fused deposition forming process.
10. The method of claim 9, wherein the step of applying the node temperature as a bulk load to the corresponding node according to the temperature distribution of the printed material during the fused deposition modeling includes:
reading a result file of the temperature distribution of the printing piece in the fused deposition forming process through the reading command;
and loading the node temperature as a body load on the corresponding node.
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