CN112883518A - Method for predicting residual stress and deformation of TIG additive and rolling composite manufactured part - Google Patents

Method for predicting residual stress and deformation of TIG additive and rolling composite manufactured part Download PDF

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CN112883518A
CN112883518A CN202110256336.4A CN202110256336A CN112883518A CN 112883518 A CN112883518 A CN 112883518A CN 202110256336 A CN202110256336 A CN 202110256336A CN 112883518 A CN112883518 A CN 112883518A
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cladding layer
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CN112883518B (en
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郭龙龙
张勇
刘峰
赵海超
魏文澜
贺雨田
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Xian Shiyou University
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Abstract

The invention provides a method for predicting residual stress and deformation of a TIG additive and rolling composite manufactured part, which comprises the following steps: the method comprises the steps of establishing a three-dimensional geometric model by using Creo software, dividing grids by using Hypermesh software, establishing a temperature field finite element model and solving based on Abaqus software, and establishing a static analysis finite element model and solving based on Abaqus software. The invention takes Abaqus general software as a platform, develops a numerical simulation modeling method of residual stress and deformation of TIG additive and rolling composite manufacturing, realizes prediction of the residual stress and deformation of TIG additive and rolling composite manufacturing parts, and can provide reference for optimization of technological parameters such as rolling reduction, rolling temperature and the like.

Description

Method for predicting residual stress and deformation of TIG additive and rolling composite manufactured part
Technical Field
The invention relates to the technical field of residual stress and deformation prediction of parts manufactured by compounding electric arc additive manufacturing and rolling, in particular to a method for predicting residual stress and deformation of a TIG additive manufacturing and rolling composite manufacturing part.
Background
The TIG additive manufacturing technology is based on the idea of dispersion and accumulation, based on three-dimensional model data of parts, and carries out point-by-point accumulation and layer-by-layer cladding through electric arc hot melting welding wires to manufacture solid parts. Compared with a selective electron beam melting technology, an electron beam cladding forming technology, a laser cladding forming technology and the like, the TIG additive manufacturing technology has the advantages of high cladding rate, low cost, suitability for manufacturing large-size parts and the like. However, in the TIG additive manufacturing process, large residual stress is formed due to rapid heating and cooling in the solidification and cooling stages, and even parts are seriously deformed and cracked, and the microstructure gradient of a cladding layer is large, so that the mechanical property of a formed part is poor. The defects seriously restrict the popularization and application of TIG additive manufacturing. Therefore, domestic and foreign scholars propose a material increase and rolling composite manufacturing process, and the feasibility of the process is proved through experimental verification.
At present, two methods of experimental measurement and numerical simulation are used for obtaining the residual stress and the deformation of a part manufactured by TIG additive and rolling composite manufacturing. The experimental measurement can only obtain the residual stress of partial points, the internal residual stress can not be obtained under the condition of not damaging parts, and the measurement error of the residual stress is larger; the numerical simulation can obtain detailed data of residual stress, deformation, plastic strain and the like of the surface and the internal point, and further provides a basis for optimizing process parameters such as rolling reduction, rolling temperature and the like. However, no research report on numerical simulation of residual stress and deformation of 316L stainless steel parts manufactured by combining TIG additive and rolling using Abaqus general software as a platform exists.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide a method for predicting the residual stress and deformation of a TIG additive and rolling composite manufactured part, which can realize the prediction of the residual stress and deformation of a TIG additive and rolling composite manufactured 316L stainless steel part and provide reference for the research of related mechanisms and the establishment of process parameters.
In order to achieve the purpose, the invention adopts the technical scheme that:
a method for predicting residual stress and deformation of a TIG additive and rolling composite manufactured part comprises the following steps;
the method comprises the following steps: establishing a three-dimensional geometric model by using Creo software;
(1) respectively establishing a three-dimensional geometric model of the roller, the substrate and each cladding layer, establishing a roller matched with each cladding layer, and assembling the roller, the substrate and the cladding layers into an assembly body;
(2) outputting the assembly body as a file in an stp format, wherein the name of the file is Assemble;
step two: dividing grids by using Hypermesh software;
(1) importing the file in the stp format into Hypermesh meshing software, geometrically cleaning the three-dimensional assembly model, and deleting and combining redundant points, lines and surfaces in the assembly model;
(2) dividing each cladding layer into hexahedral meshes, wherein the mesh size along the length direction of the cladding layer is 1/3 of the length of the deposited cladding layer within 1 second, and creating a corresponding volume mesh set for each cladding layer unit, which are named as follows: w1、W2、W3、……，WiI is the number of the cladding layers;
(3) dividing the substrate into two parts, namely a region adjacent to the cladding layer and a region far away from the cladding layer, along the length and width directions by taking the width of the cladding layer 1.5 times from the edge of the cladding layer as a boundary line, arranging relatively fine grids in the region adjacent to the cladding layer, and arranging sparse grids in the region far away from the cladding layer, ensuring the continuity of nodes in the region adjacent to the cladding layer and the region far away from the cladding layer by adopting a grid transition mode, and arranging the substrate grids in a grid set substrate;
(4) will be provided withEach roll is divided into hexahedral meshes, and the hexahedral meshes are sequentially arranged in a mesh set Z1、Z2、Z3、……，ZiAnd i is the number of the cladding layers;
(5) combining and deleting repeated nodes and grids, taking grids of the substrate and the cladding layer as an inp file named as T-assembly, and outputting all grids as inp files named as S-assembly;
step three: establishing a temperature field finite element model based on Abaqus software and solving;
(1) importing the T-assembly. inp file into Abaqus software, and naming the generated model as Temp;
(2) defining a Boltzmann constant, an absolute zero degree and a unit type;
(3) defining thermophysical performance parameters of the substrate and the cladding layer along with temperature change;
(4) establishing a heat conduction analysis step, wherein the 1 st analysis step is an initial steady state analysis step, the 2 nd analysis step is a TIG cladding analysis step, and the analysis step number N of each cladding layer iskIs equal to the length L of the cladding layerkDivided by the cladding velocity VkCreating a roll motion analysis step and a cooling analysis step after the last analysis step of each cladding layer, and totally establishing the number N of the analysis steps as 1+2i + N1+N2+N3+……+Ni；
(5) Sequentially creating a unit set along the length direction of each cladding layer by taking the dimension of 1 time of welding speed as the length, and forming the cladding layer WkAre named as W-k _1 and W-k _2 … … W-k _ j in sequence, wherein j is a cladding layer WkThe jth cell set of (1);
(6) the cells of the deposition layer in the 1 st analysis step are all killed, 2k + N1+N2+……+Nk-1Activation of the cladding layer N successively from one analysis stepkThe analysis step of the mill roll movement and the cooling analysis step have no unit life and death change;
(7) setting an initial temperature 293K for all grids;
(8) setting the self-defined body heat flow density for all grids, wherein the amplitude is 1;
(9) the surfaces contacting with air are all arranged as convection and radiation surfaces, and the convection coefficient is 15W/m2Radiation coefficient 0.7, ambient temperature 293K;
(10) creating a jobfile, selecting a storage path corresponding to the hot-flow program, submitting the jobfile, and solving to obtain a cladding process and a temperature field after cooling is finished;
step four: establishing a static analysis finite element model based on Abaqus software and solving;
(1) importing the S-assembly. inp file into Abaqus software, and naming the generated model as Stress;
(2) defining unit types of a cladding layer and a substrate;
(3) defining thermal expansion coefficients of a cladding layer, a region of a substrate close to the cladding layer and a region of the substrate far away from the cladding layer, endowing elastic-plastic performance parameters to the cladding layer and the region close to the cladding layer, endowing only elastic performance parameters to materials far away from the cladding layer, and defining elastic parameters and density of the roller;
(4) establishing static force field analysis steps, wherein the time corresponding to each static force field analysis step is the same as that of the temperature field analysis step, namely: the 1 st analysis step is an initial steady-state step, the 2 nd analysis step is a TIG cladding analysis step, and the analysis step number N of each cladding layerkIs equal to the length L of the cladding layerkDivided by the cladding velocity VkCreating a roll motion analysis step and a cooling analysis step after the last analysis step of each cladding layer, and totally establishing the number N of the analysis steps as 1+2i + N1+N2+N3+……+Ni；
(5) The dimension of the cladding layer deposited in 1 second is taken as the length, and a unit set is sequentially created along the length direction of each cladding layer, and the cladding layer WkAre named as W-k _1 and W-k _2 … … W-k _ j in sequence, wherein j is a cladding layer WkThe jth cell set of (1);
(6) the units of the deposition layer in the 1 st analysis step are killed, the unit sets of the cladding layer Nk are activated successively from the 2k + N1+ N2+ … … + Nk-1 analysis steps, 1 unit set is activated in each analysis step, and no unit life and death change exists in the roll movement analysis step and the cooling analysis step;
(7) setting a predefined temperature field, reading in an odb result file obtained by calculating the temperature field, mapping a temperature field calculation result to a stress field, and taking the temperature field calculation result as a load calculated by the stress field;
(8) defining an initial temperature, the value of which is set to ambient temperature 293K;
(9) respectively by rollers ZkEstablishing 2 reference points named as RP-k and MRP-k by taking the circle center of the end face as a reference, and establishing a local coordinate Csys-k of each coordinate axis parallel to the global coordinate axis by taking the RP-k as a coordinate origin;
(10) to roll ZkAll units of (a) are coupled with a reference point RP-k, thereby establishing rigid body constraint;
(11) establishing a reference point MRP-k and a reference point RP-k as motion coupling constraint by taking the reference point MRP-k as a control point, and coupling the translational motion of the two reference points in the direction of X, Y, Z;
(12) 2k + N1+N2+……+Nk-1From the analysis step, the roll Z corresponding to the k-th cladding layerkStarting the movement, setting the speed of the reference point MRP-k in the direction of X, Y, Z under the global coordinate, ensuring the 2k + N1+N2+……+Nk-1At the end of each analysis step, roller ZkThe clad layer is just beginning to be rolled and the 1+2k + N is modified1+N2+……+Nk-1The velocity of each analysis step is set to V along the length direction of the cladding layerkThe velocity in the width and thickness directions of the cladding layer is set to 0 from 2k + N1+N2+……+NkThe analysis step does not work for this boundary condition;
(13) 2k + N1+N2+……+Nk-1Setting a reference point RP-k around the roller Z under the local coordinate Csys-kkThe rotation speed of the axes with coincident axes being from 2k + N1+N2+……+NkThe analysis step does not work for this boundary condition;
(14) adding mechanical constraint conditions to the matrix according to actual conditions to avoid rigid motion of the matrix;
(15) and (4) creating a static analysis joba, submitting to solve, and obtaining the residual stress and deformation distribution in the cladding process and after cooling.
The invention has the beneficial effects that:
1. in the grid division process, the width of the cladding layer 1.5 times of the edge of the cladding layer is taken as a boundary line, the substrate is divided into two parts, namely a region adjacent to the cladding layer and a region far away from the cladding layer, the grid arrangement of the region adjacent to the cladding layer is relatively fine, the grid arrangement of the region far away from the cladding layer is sparse, the grid nodes of the region adjacent to the cladding layer and the region far away from the cladding layer are ensured to be continuous by adopting a grid transition mode, and the calculation time is saved on the premise of not influencing the solving precision.
2. When the model is established, each cladding layer corresponds to one roller, so that the defect that the solution of a static analysis finite element model is difficult to converge due to the fact that each cladding layer shares one roller is overcome;
3. the residual stress and deformation distribution of 316L stainless steel parts manufactured by TIG additive and rolling composite can be predicted.
Drawings
FIG. 1 is a schematic diagram of a modeling process of the present invention.
Fig. 2 is a schematic diagram of the three-dimensional geometric model building according to the embodiment of the invention.
FIG. 3 is a schematic diagram of a temperature field grid T-assembly according to an exemplary embodiment of the present invention.
FIG. 4 is a schematic cross-sectional view taken along line X-Y of FIG. 3 according to an embodiment of the present invention.
FIG. 5 is a diagram of a stress field grid S-assembly according to an exemplary embodiment of the present invention.
FIG. 6 shows the temperature simulation results of the deposition process of the 2 nd cladding layer in the example of the present invention.
FIG. 7 shows the results of temperature simulation of the 4 th cladding layer deposition process in the example of the present invention.
FIG. 8 is a result of temperature simulation of the end of deposition cooling of the 7 th cladding layer in the example of the practice of the present invention.
FIG. 9 shows the simulation result of X-direction deformation of the deposition process of the 2 nd cladding layer in the embodiment of the present invention.
Fig. 10 is an enlarged view of a deformation of the roll of fig. 9 in an example of the present invention.
Fig. 11 shows the total deformation after the composite manufacturing in the embodiment of the present invention is completed.
Fig. 12 shows the deformation in the X-axis direction after the composite production is completed in the example of the present invention.
Fig. 13 shows the deformation in the Y-axis direction after the completion of the composite fabrication in the embodiment of the present invention.
Fig. 14 shows the deformation in the Z-axis direction after the composite production is completed in the embodiment of the present invention.
Fig. 15 shows Von Mises stress after composite fabrication in an example embodiment of the present invention.
Fig. 16 shows residual stress in the X-axis direction after the composite fabrication is completed in the example of the present invention.
Fig. 17 shows residual stress in the Y-axis direction after completion of composite fabrication in the example embodiment of the present invention.
Fig. 18 shows residual stress in the Z-axis direction after completion of composite fabrication in the example embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
The modeling process is shown in FIG. 1 and includes: establishing a three-dimensional geometric model, meshing, establishing a temperature field finite element model and solving, and establishing a static analysis finite element model and solving, wherein the method specifically comprises the following steps:
step 1: establishing a three-dimensional geometric model;
(1) respectively establishing three-dimensional geometric models of the roller, the matrix and the cladding layers by using three-dimensional modeling software Creo, and assembling the three-dimensional geometric models into an assembly body; the roller in the geometric model is a cylinder, and the inner diameter, the outer diameter and the length of the roller are respectively 3mm, 5mm and 7 mm; the substrate is a cuboid, and the length, width and height of the substrate are respectively 100mm, 35mm and 10 mm; the length, width and layer height of the cladding layer are respectively 90mm, 4.5mm and 2mm, and the cladding layer comprises 7 cladding layers and 7 rollers in total, as shown in figure 2;
(2) and outputting the assembly as a file in an stp format, wherein the file is named as Assembly.
Step two: grid division;
(1) importing the file in the stp format into Hypermesh meshing software, geometrically cleaning the three-dimensional assembly body model, and deleting and combining redundant points, lines and surfaces in the three-dimensional assembly body;
(2) as shown in fig. 3 and 4, each cladding layer is divided into hexahedral meshes, the mesh size along the length direction of the cladding layer is 1/3 of the length of the deposited cladding layer for 1 second, the specific size is 1mm, the mesh sizes along the thickness direction and the width direction of the cladding layer are 1mm and 0.8mm respectively, and a corresponding volume mesh set is created for each unit of the cladding layer, and the volume mesh sets are named in sequence as: w1、W2、W3、……，W7；
(3) As shown in fig. 3 and 4, the substrate is divided into two parts, namely a region adjacent to the cladding layer and a region far away from the cladding layer, along the length and width directions by taking the cladding layer width 1.5 times from the edge of the cladding layer as a boundary, the grid in the region adjacent to the cladding layer is relatively fine, the grid size is 1.2mm × 1.4mm × 1mm, the grid in the region far away from the cladding layer is sparse, the grid size is 2.8mm × 1.5mm × 1mm, grid nodes in the region adjacent to the cladding layer and the region far away from the cladding layer are ensured to be continuous by adopting a grid transition mode, and the substrate grid is arranged in a grid set substrate;
(4) and combining and deleting repeated nodes and grids, and outputting the divided grids as inp files with names of Assemble.
And step 3: establishing a temperature field finite element model;
(1) importing the T-assembly. inp file into Abaqus software, and naming the generated model as Temp;
(2) define Boltzmann constant 5.67 × 10-8Absolute zero-273K, cell type DC3D 8;
(3) the thermophysical performance parameters of the matrix and the cladding layer along with the temperature change are defined, and specific parameters are quoted from Wenchun junction, Yucia Zhang, Wangchunk Wo.
(4) Establishing a heat conduction analysis step, wherein the 1 st analysis step is an initial steady state analysis step, the 2 nd analysis step is a TIG cladding analysis step, and each stepNumber of analysis steps N of cladding layerkIs equal to the length L of the cladding layerkDivided by the cladding velocity VkCreating a roll motion analysis step and a cooling analysis step after the last analysis step of each cladding layer, and totally establishing the number N of the analysis steps as 1+2i + N1+N2+N3+……+Ni；
(5) Sequentially creating unit sets along the length direction of each cladding layer by taking the size of 1 time of welding speed as the length, and sequentially naming the unit sets of the cladding layer Wk as W-k _1 and W-k _2 … … W-k _ j (wherein W-k is the name of the corresponding cladding layer, and j is the jth unit set of the cladding layer);
(6) the cells of the deposition layer in the 1 st analysis step are all killed, 2k + N1+N2+……+Nk-1Activation of the cladding layer N successively from one analysis stepkThe analysis step of the mill roll movement and the cooling analysis step have no unit life and death change;
(7) setting an initial temperature 293K for all grids;
(8) the surfaces contacting with air are all arranged as convection and radiation surfaces, and the convection coefficient is 15W/m2Radiation coefficient 0.7, ambient temperature 293K;
(9) setting the self-defined body heat flow density for all grids, wherein the amplitude is 1;
(10) writing a double-ellipsoid heat source program by using Fortran language, wherein the deposition speed is along the positive direction of a Z axis, the welding gun coordinate at any moment is taken as a boundary, and the heat flow density q along the positive direction of the Z axisf(x, y, Z), heat flux density q in the negative direction of the Z axisr(x, y, z) are calculated according to the formulas (1) and (2) respectively;
Figure BDA0002968414190000101
Figure BDA0002968414190000102
in the formula, qrHeat flux density in the positive (x, y, Z) -Z-axis direction, qf(x,y,z)—Heat flux density in the negative direction of the Z axis, Q-arc heat power, ff、fr-heat flow density distribution coefficient, x0,y0,z0Coordinates of the start of the welding gun, af、arB, c-heat flow density shape parameter;
Q＝UIη
u-welding voltage, I-welding current and eta-thermal efficiency;
(11) creating a jobfile of the temperature field, selecting a heat source program written in Fortran language at the user defined file, intersecting the jobfile, and solving to obtain the temperature field, as shown in fig. 6, 7 and 8.
And 4, step 4: establishing a static analysis finite element model;
(1) importing the S-assembly. inp file into Abaqus software, and naming the generated model as Stress;
(2) defining the unit type of the roller, the cladding layer and the substrate as C3D 8R;
(3) defining thermal expansion coefficient and elastic-plastic parameters of cladding layer and substrate area close to the cladding layer, and defining thermal expansion coefficient and elastic parameter of substrate area far from the cladding layer, wherein the specific parameters are quoted from Wenchun junction, Yucai Zhang, Wanchuck Wo]International Journal of Pressure Vessels and Ping,2012,92: 56-62; defining the elastic modulus of the roller as 1000GPa, the Poisson ratio as 0.3 and the density as 7800kg/m3；
(4) Establishing static force field analysis steps, wherein the time corresponding to each static force field analysis step is the same as that of the temperature field analysis step, namely: the 1 st analysis step is an initial steady-state step, the 2 nd analysis step is a TIG cladding analysis step, and the analysis step number N of each cladding layerkIs equal to the length L of the cladding layerkDivided by the cladding velocity VkCreating a roll motion analysis step and a cooling analysis step after the last analysis step of each cladding layer, and totally establishing the number N of the analysis steps as 1+2i + N1+N2+N3+……+Ni；
(5) Sequentially creating unit sets along the length direction of each cladding layer by taking the size of the cladding layer deposited in 1 second as the length, wherein the unit sets of the cladding layer Wk are sequentially named as W-k _1 and W-k _2 … … W-k _ j (wherein W-k is the name of the corresponding cladding layer, and j is the jth unit set of the cladding layer);
(6) the units of the deposition layer in the 1 st analysis step are killed, the unit sets of the cladding layer Nk are activated successively from the 2k + N1+ N2+ … … + Nk-1 analysis steps, 1 unit set is activated in each analysis step, and no unit life and death change exists in the roll movement analysis step and the cooling analysis step;
(7) setting a predefined temperature field, reading in an odb result file obtained by calculating the temperature field, and mapping a temperature field calculation result to a stress field to serve as a load calculated by the stress field;
(8) defining an initial temperature, the value of which is set to ambient temperature 293K;
(9) respectively by rollers ZkEstablishing 2 reference points named as RP-k and MRP-k by taking the circle center of the end face as a reference, and establishing a local coordinate Csys-k of each coordinate axis parallel to the global coordinate axis by taking the RP-k as a coordinate origin;
(10) to roll ZkAll units of (a) are coupled with a reference point RP-k, thereby establishing rigid body constraint;
(11) establishing a reference point MRP-k and a reference point RP-k as motion coupling constraint by taking the reference point MRP-k as a control point, and coupling the translational motion of the two reference points in the direction of X, Y, Z;
(12) 2k + N1+N2+……+Nk-1From the analysis step, the roll Z corresponding to the k-th cladding layerkStarting the movement, setting the speed of the reference point MRP-k in the direction of X, Y, Z under the global coordinate, ensuring the 2k + N1+N2+……+Nk-1At the end of each analysis step, roller ZkThe clad layer is just beginning to be rolled and the 1+2k + N is modified1+N2+……+Nk-1The velocity of each analysis step is set to V along the length direction of the cladding layerkThe velocity in the width and thickness directions of the cladding layer is set to 0 from 2k + N1+N2+……+NkThe analysis step does not work for this boundary condition;
(13) 2k + N1+N2+……+Nk-1Setting a reference point RP-k around the roller Z under the local coordinate Csys-kkThe rotation speed of the axes with coincident axes being from 2k + N1+N2+……+NkThe analysis step does not work for this boundary condition;
(14) adding mechanical constraint conditions to the matrix according to actual conditions to avoid rigid motion of the model;
(15) a static analysis joba is created and submitted to solution, with simulated deformations as shown in fig. 9-14 and simulated residual stresses as shown in fig. 15-18.
The invention provides a numerical simulation modeling method for residual stress and deformation of 316L stainless steel parts manufactured by TIG additive and rolling in a combined mode, which can solve and predict a temperature field, residual stress and deformation evolution rule in the TIG additive and rolling combined manufacturing process and has application potential in the aspects of TIG additive and rolling combined manufacturing mechanism research and engineering process parameter formulation.

Claims (3)

1. A method for predicting residual stress and deformation of a TIG additive and rolling composite manufactured part is characterized by comprising the following steps;
the method comprises the following steps: establishing a three-dimensional geometric model by using Creo software;
(1) respectively establishing a three-dimensional geometric model of the roller, the substrate and each cladding layer, establishing a roller matched with each cladding layer, and assembling the roller, the substrate and the cladding layers into an assembly body;
(2) outputting the assembly body as a file in an stp format, wherein the name of the file is Assemble;
step two: dividing grids by using Hypermesh software;
(1) importing the file in the stp format into Hypermesh meshing software, geometrically cleaning the three-dimensional assembly model, and deleting and combining redundant points, lines and surfaces in the assembly model;
(2) dividing each cladding layer into hexahedral cells, the size of the cells in the length direction of the cladding layer being 1/3 of the length of the deposited cladding layer 1 second, creating pairs for each cladding layer cellThe corresponding volume grid set is named as: w1、W2、W3、……，WiI is the number of the cladding layers;
(3) dividing the substrate into two parts, namely a region adjacent to the cladding layer and a region far away from the cladding layer, along the length and width directions by taking the width of the cladding layer 1.5 times from the edge of the cladding layer as a boundary line, arranging relatively fine grids in the region adjacent to the cladding layer, and arranging sparse grids in the region far away from the cladding layer, ensuring the continuity of nodes in the region adjacent to the cladding layer and the region far away from the cladding layer by adopting a grid transition mode, and arranging the substrate grids in a grid set substrate;
(4) dividing each roller into hexahedral meshes, and sequentially placing the hexahedral meshes in a mesh set Z1、Z2、Z3、……，ZiAnd i is the number of the cladding layers;
(5) combining and deleting repeated nodes and grids, taking grids of the substrate and the cladding layer as an inp file named as T-assembly, and outputting all grids as inp files named as S-assembly;
step three: establishing a temperature field finite element model based on Abaqus software and solving;
(1) importing the T-assembly. inp file into Abaqus software, and naming the generated model as Temp;
(2) defining a Boltzmann constant, an absolute zero degree and a unit type;
(3) defining thermophysical performance parameters of the substrate and the cladding layer along with temperature change;
(4) establishing a heat conduction analysis step, wherein the 1 st analysis step is an initial steady state analysis step, the 2 nd analysis step is a TIG cladding analysis step, and the analysis step number N of each cladding layer iskIs equal to the length L of the cladding layerkDivided by the cladding velocity VkCreating a roll motion analysis step and a cooling analysis step after the last analysis step of each cladding layer, and totally establishing the number N of the analysis steps as 1+2i + N1+N2+N3+……+Ni；
(5) Sequentially creating unit sets along the length direction of each cladding layer by taking the dimension of 1 time of welding speed as the length, and sequentially naming the unit sets of the cladding layers Wk as W-k _1W-k _2 … … W-k _ j, wherein j is the cladding layer WkThe jth cell set of (1);
(6) the cells of the deposition layer in the 1 st analysis step are all killed, 2k + N1+N2+……+Nk-1Activation of the cladding layer N successively from one analysis stepkThe analysis step of the mill roll movement and the cooling analysis step have no unit life and death change;
(7) setting an initial temperature 293K for all grids;
(8) setting the self-defined body heat flow density for all grids, wherein the amplitude is 1;
(9) the surfaces contacting with air are all arranged as convection and radiation surfaces, and the convection coefficient is 15W/m2Radiation coefficient 0.7, ambient temperature 293K;
(10) creating a jobfile, selecting a storage path corresponding to the hot-flow program, submitting the jobfile, and solving to obtain a cladding process and a temperature field after cooling is finished;
step four: establishing a static analysis finite element model based on Abaqus software and solving;
(1) importing the S-assembly. inp file into Abaqus software, and naming the generated model as Stress;
(2) defining unit types of a cladding layer and a substrate;
(3) defining thermal expansion coefficients of a cladding layer, a region close to the cladding layer and a region far away from the cladding layer, endowing the cladding layer and the region close to the cladding layer with elastic-plastic performance parameters, endowing materials far away from the cladding layer with elastic performance parameters, and defining the elastic parameters and the density of the roller;
(4) establishing static force field analysis steps, wherein the time corresponding to each static force field analysis step is the same as that of the temperature field analysis step, namely: the 1 st analysis step is an initial steady-state step, the 2 nd analysis step is a TIG cladding analysis step, and the analysis step number N of each cladding layerkIs equal to the length L of the cladding layerkDivided by the cladding velocity VkCreating a roll motion analysis step and a cooling analysis step after the last analysis step of each cladding layer, and totally establishing the number N of the analysis steps as 1+2i + N1+N2+N3+……+Ni；
(5) Taking the dimension of the cladding layer deposited in 1 second as the length, sequentially creating unit sets along the length direction of each cladding layer, sequentially naming the unit sets of the cladding layer Wk as W-k _1 and W-k _2 … … W-k _ j, wherein j is the cladding layer WkThe jth cell set of (1);
(6) the units of the deposition layer in the 1 st analysis step are killed, the unit sets of the cladding layer Nk are activated successively from the 2k + N1+ N2+ … … + Nk-1 analysis steps, 1 unit set is activated in each analysis step, and no unit life and death change exists in the roll movement analysis step and the cooling analysis step;
(7) setting a predefined temperature field, reading in an odb result file obtained by calculating the temperature field, mapping a temperature field calculation result to a stress field, and taking the temperature field calculation result as a load calculated by the stress field;
(8) defining an initial temperature, the value of which is set to ambient temperature 293K;
(9) respectively by rollers ZkEstablishing 2 reference points named as RP-k and MRP-k by taking the circle center of the end face as a reference, and establishing a local coordinate Csys-k of each coordinate axis parallel to the global coordinate axis by taking the RP-k as a coordinate origin;
(10) to roll ZkAll units of (a) are coupled with a reference point RP-k, thereby establishing rigid body constraint;
(11) establishing a reference point MRP-k and a reference point RP-k as motion coupling constraint by taking the reference point MRP-k as a control point, and coupling the translational motion of the two reference points in the direction of X, Y, Z;
(12) 2k + N1+N2+……+Nk-1From the analysis step, the roll Z corresponding to the k-th cladding layerkStarting the movement, setting the speed of the reference point MRP-k in the direction of X, Y, Z under the global coordinate, ensuring the 2k + N1+N2+……+Nk-1At the end of each analysis step, roller ZkThe clad layer is just beginning to be rolled and the 1+2k + N is modified1+N2+……+Nk-1The velocity of each analysis step is set to V along the length direction of the cladding layerkThe velocity in the width and thickness directions of the cladding layer is set to 0 from 2k + N1+N2+……+NkThe analysis step does not work for this boundary condition;
(13) 2k + N1+N2+……+Nk-1Setting a reference point RP-k around the roller Z under the local coordinate Csys-kkThe rotation speed of the axes with coincident axes being from 2k + N1+N2+……+NkThe analysis step does not work for this boundary condition;
(14) adding mechanical constraint conditions to the matrix according to actual conditions to avoid rigid motion of the matrix;
(15) and (4) creating a static analysis joba, submitting to solve, and obtaining the residual stress and deformation distribution in the cladding process and after cooling.
2. A method for predicting residual stress and deformation of a TIG additive and rolling composite manufactured part according to claim 1, characterized in that a roller matched with each cladding layer is established, so that the problem that the solution of a finite element model for static analysis is not easy to converge is solved.
3. The method for predicting residual stress and deformation of a TIG additive and rolling composite manufactured part according to claim 1, characterized in that in the meshing process, the width of the cladding layer 1.5 times from the edge of the cladding layer is taken as a boundary line, the substrate is divided into two parts, namely a region adjacent to the cladding layer and a region far away from the cladding layer, the mesh arrangement of the region adjacent to the cladding layer is relatively fine, the mesh arrangement of the region far away from the cladding layer is sparse, the mesh nodes of the region adjacent to the cladding layer and the region far away from the cladding layer are ensured to be continuous by adopting a mesh transition mode, and the calculation time is saved on the premise of not influencing the solution precision.
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