CN112883518B - Method for predicting residual stress and deformation of TIG (tungsten inert gas) additive and rolled composite manufactured part - Google Patents

Method for predicting residual stress and deformation of TIG (tungsten inert gas) additive and rolled composite manufactured part Download PDF

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CN112883518B
CN112883518B CN202110256336.4A CN202110256336A CN112883518B CN 112883518 B CN112883518 B CN 112883518B CN 202110256336 A CN202110256336 A CN 202110256336A CN 112883518 B CN112883518 B CN 112883518B
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cladding layer
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CN112883518A (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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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/10—Geometric CAD
    • G06F30/17—Mechanical parametric or variational design
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2111/00—Details relating to CAD techniques
    • G06F2111/04—Constraint-based CAD
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2111/00—Details relating to CAD techniques
    • G06F2111/10—Numerical modelling
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2113/00—Details relating to the application field
    • G06F2113/10—Additive manufacturing, e.g. 3D printing
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
    • G06F2119/14—Force analysis or force optimisation, e.g. static or dynamic forces
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02P10/00—Technologies related to metal processing
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Abstract

The invention provides a method for predicting residual stress and deformation of a TIG additive and rolling composite manufacturing 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. According to the invention, abaqus universal software is used as a platform, a numerical simulation modeling method for the residual stress and deformation of the TIG additive and rolling composite manufacturing is developed, the prediction of the residual stress and deformation of the part manufactured by the TIG additive and rolling composite manufacturing is realized, and references can be provided for the optimization of technological parameters such as rolling reduction, rolling temperature and the like.

Description

Method for predicting residual stress and deformation of TIG (tungsten inert gas) additive and rolled composite manufactured part
Technical Field
The invention relates to the technical field of prediction of residual stress and deformation of parts manufactured by arc additive and rolling composite manufacturing, in particular to a method for predicting the residual stress and deformation of a TIG additive and rolling composite manufacturing part.
Background
The TIG additive manufacturing technology is based on the ideas of discrete and stacking, and based on three-dimensional model data of parts, performs point-by-point stacking and layer-by-layer cladding by arc hot melting welding wires to manufacture solid parts. Compared with the selective electron beam melting technology, the electron beam cladding forming technology, the 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 process of manufacturing the TIG additive, large residual stress can be formed due to rapid heating and cooling in the solidification and cooling stages, the part can be seriously deformed and cracked even, the microstructure gradient of the cladding layer is large, and the mechanical property of a formed part is poor. These shortcomings severely restrict the popularization and application of TIG additive manufacturing. For this reason, the composite manufacturing process of additive and rolling is proposed by the students in China and the inside and outside, and the feasibility of the process is proved through experiments.
At present, the methods for obtaining the residual stress and deformation of the part manufactured by combining TIG material increase and rolling have two methods of experimental measurement and numerical simulation. The experimental measurement only can obtain the residual stress of part points, the residual stress in the part cannot be obtained under the condition of not damaging the part, and the measurement error of the residual stress is larger; the numerical simulation can obtain detailed data such as residual stress, deformation, plastic strain and the like of the surface and internal points, and further provides basis for optimization of technological parameters such as roll reduction, rolling temperature and the like. However, no research and report on numerical simulation of residual stress and deformation of a 316L stainless steel part manufactured by combining TIG additive and rolling have been carried out by using Abaqus general software as a platform.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention aims to provide a method for predicting residual stress and deformation of a TIG additive and rolling composite manufacturing part, which can realize the prediction of the residual stress and deformation of a TIG additive and rolling composite manufacturing 316L stainless steel part and provides references for the research of related mechanisms and the formulation of technological parameters.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
a method of predicting TIG additive and rolling composite fabrication residual stress and deformation comprising the steps of;
step one: establishing a three-dimensional geometric model by using Creo software;
(1) Respectively establishing three-dimensional geometric models of the roller, the matrix and each cladding layer, establishing a roller matched with each cladding layer, and assembling the roller, the matrix and the cladding layers into an assembly;
(2) Outputting the assembly as a file in the stp format, wherein the name is an assembly;
step two: dividing grids by Hypermesh software;
(1) Importing a file in a stp format into Hypermesh grid division software, geometrically cleaning a three-dimensional assembly model, deleting and merging redundant points, lines and surfaces in the assembly model;
(2) Dividing each cladding layer into hexahedral grids, wherein the grid size along the length direction of the cladding layer is 1/3 of the length of the cladding layer deposited in 1 second, and creating a corresponding volume grid set for each cladding layer unit, which is sequentially named as: w (W) 1 、W 2 、W 3 、……，W i I is the number of cladding layers;
(3) Dividing a substrate into two parts, namely a nearby cladding layer area and a far cladding layer area, along the length and width directions by taking the width of the cladding layer which is 1.5 times from the edge of the cladding layer as a boundary line, arranging grids in the nearby cladding layer area in a relatively fine manner, arranging grids in the far cladding layer area in a sparse manner, ensuring that nodes in the nearby cladding layer area and the far cladding layer area are continuous in a grid transition manner, and arranging the grids of the substrate in a grid set substrate;
(4) Dividing each roller into hexahedral meshes, and sequentially placing the hexahedral meshes in a mesh set Z 1 、Z 2 、Z 3 、……，Z i In, i is the number of cladding layers;
(5) Merging and deleting repeated nodes and grids, and outputting grids of a matrix and a cladding layer as an inp file, which is named as T-assembly, and outputting all grids as an inp file, which is named as S-assembly;
step three: establishing a temperature field finite element model and solving based on Abaqus software;
(1) Importing the T-assembly 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 the thermophysical performance parameters of the substrate and the cladding layer along with the temperature change;
(4) Establishing a thermal 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 number of analysis steps of each cladding layer is N k Equal to the cladding layerLength L k Divided by cladding layer velocity V k After the last analysis step of each cladding layer, a roll motion analysis step and a cooling analysis step are created, and the total number of analysis steps is created, wherein N=1+2i+N 1 +N 2 +N 3 +……+N i ；
(5) With a size of 1 time of welding speed as a length, a unit set is sequentially created along the length direction of each cladding layer, and the cladding layers W k The unit sets are named W-k_1, W-k_ … … W-k_j in sequence, where j is the cladding layer W k Is the j-th set of cells;
(6) The units of the deposited layer in analysis step 1 are all killed, 2k+N 1 +N 2 +……+N k-1 Sequentially activating the cladding layer N from each analysis step k 1 unit set is activated in each analysis step, and no unit changes in the roll motion analysis step and the cooling analysis step;
(7) Setting initial temperature 293K for all grids;
(8) Setting self-defined heat flux density of the body for all grids, wherein the amplitude is 1;
(9) The surfaces contacted with the air are all convection and radiation surfaces, and the convection coefficient is 15W/m 2 Emissivity 0.7, ambient temperature 293K;
(10) Creating a job file, selecting a storage path corresponding to a heat flow program, submitting the job file, and solving to obtain a cladding process and a temperature field after cooling is finished;
step four: establishing a static analysis finite element model and solving based on Abaqus software;
(1) Importing the S-assembly file into Abaqus software, and naming the generated model as Stress;
(2) Defining the unit type of the cladding layer and the matrix;
(3) Defining the thermal expansion coefficients of a cladding layer, a substrate close to the cladding layer area and a substrate far away from the cladding layer area, endowing elastic-plastic performance parameters to the cladding layer and the adjacent cladding layer area, endowing elastic performance parameters only to materials far away from the cladding layer area, and defining the elastic parameters and the density of a roller;
(4) Establishing a static field analysis step, each static analysisThe corresponding time of the step is the same as 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 number of analysis steps of each cladding layer is N k Equal to the length L of the cladding layer k Divided by cladding layer velocity V k After the last analysis step of each cladding layer, a roll motion analysis step and a cooling analysis step are created, and the total number of analysis steps is created, wherein N=1+2i+N 1 +N 2 +N 3 +……+N i ；
(5) The size of the cladding layer deposited for 1 second is taken as the length, a unit set is sequentially created along the length direction of each cladding layer, and the cladding layers W k The unit sets are named W-k_1, W-k_ … … W-k_j in sequence, where j is the cladding layer W k Is the j-th set of cells;
(6) The units of the deposition layer in the 1 st analysis step are killed, the 2k+N1+N2+ … … +Nk-1 analysis steps start to activate the unit set of the cladding layer Nk successively, each analysis step activates 1 unit set, and the roller motion analysis step and the cooling analysis step have no unit death change;
(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 stress field calculation result as a stress field calculation load;
(8) Defining an initial temperature, wherein the value of the initial temperature is set to be the ambient temperature 293K;
(9) Respectively by rollers Z k 2 reference points are established by taking the circle center of the end surface as a reference, are named as RP-k and MRP-k, and a local coordinate Csys-k, in which each coordinate axis is parallel to the global coordinate axis, is established by taking the RP-k as the origin of coordinates;
(10) Roll Z k Is coupled with a reference point RP-k, thereby establishing a rigid body constraint;
(11) Taking a reference point MRP-k as a control point, establishing the reference point MRP-k and the reference point RP-k as motion coupling constraints, and coupling translational motions of the two reference points in the X, Y, Z direction;
(12) 2k+N 1 +N 2 +……+N k-1 The analysis step starts, and the roller Z corresponding to the kth cladding layer k Starting the movement, setting a reference point in global coordinatesThe speed of MRP-k in X, Y, Z direction ensures 2k+N 1 +N 2 +……+N k-1 At the end of the analysis steps, roll Z k The cladding layer is rolled and pressed at the beginning, and the 1+2k+N is modified 1 +N 2 +……+N k-1 The speed of each analysis step was set to V in the longitudinal direction of the cladding layer k The speed in the width and thickness directions of the cladding layer was 0, and was 2k+N 1 +N 2 +……+N k The analysis step does not function with this boundary condition;
(13) 2k+N 1 +N 2 +……+N k-1 Starting with the analysis step, a reference point RP-k is set at a local coordinate Csys-k around the roll Z k The rotation speed of the coordinate axes with the coincident axes is from 2k+N 1 +N 2 +……+N k The analysis step does not function with this boundary condition;
(14) According to the actual situation, mechanical constraint conditions are added to the matrix, so that the matrix is prevented from rigid motion;
(15) And creating a static force analysis job, submitting the static force analysis job to solve the static force analysis job, and obtaining residual stress and deformation distribution after the cladding process and cooling are finished.
The beneficial effects of the invention are as follows:
1. in the grid dividing process, the substrate is divided into two parts, namely a nearby cladding layer area and a far cladding layer area, by taking the width of the cladding layer which is 1.5 times that of the edge of the cladding layer as a boundary line, the grids of the nearby cladding layer area are arranged relatively densely, the grids of the far cladding layer area are arranged sparsely, the grid nodes of the nearby cladding layer area and the far cladding layer area are ensured to be continuous in a grid transition mode, and the calculation time is saved on the premise that the solving precision is not influenced.
2. When a model is built, each cladding layer corresponds to one roller, so that the defect that the solution of the static analysis finite element model is difficult to converge due to the fact that each cladding layer shares one roller is avoided;
3. the residual stress and deformation distribution of the TIG additive and rolling composite manufactured 316L stainless steel part can be predicted.
Drawings
FIG. 1 is a schematic diagram of a modeling flow of the present invention.
Fig. 2 is a schematic diagram of three-dimensional geometric modeling of an embodiment of the present invention.
FIG. 3 is a schematic diagram of a temperature field grid T-assembly in accordance with an exemplary embodiment of the present invention.
FIG. 4 is a schematic cross-sectional view of the 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 of an embodiment of the present invention.
FIG. 6 is a graph showing the results of temperature simulation of the deposition process of the cladding layer of the 2 nd pass in the embodiment of the present invention.
FIG. 7 is a graph showing the results of temperature simulation of the deposition process of the 4 th cladding layer in the embodiment of the present invention.
FIG. 8 is a graph showing the results of temperature simulation of the end of deposition cooling of the 7 th cladding layer in the embodiment of the present invention.
FIG. 9 is a simulation result of the 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 the deformation of the roll of fig. 9 in an embodiment of the invention.
Fig. 11 shows the overall modification after the end of the composite manufacturing in the embodiment of the present invention.
Fig. 12 shows deformation in the X-axis direction after the completion of composite manufacturing in the embodiment of the present invention.
Fig. 13 shows the Y-axis deformation after the completion of the composite manufacturing in the embodiment of the present invention.
Fig. 14 shows the deformation in the Z-axis direction after the completion of the composite manufacturing in the embodiment of the present invention.
Fig. 15 shows Von Mises stress after the composite fabrication is completed in an example of the present invention.
Fig. 16 shows the residual stress in the X-axis direction after the completion of the composite manufacturing in the embodiment of the present invention.
Fig. 17 shows the residual stress in the Y-axis direction after the end of the composite manufacturing in the embodiment of the present invention.
Fig. 18 shows the residual stress in the Z-axis direction after the completion of the composite manufacturing in the embodiment of the present invention.
Detailed Description
The invention is described in further detail below with reference to the accompanying drawings.
The modeling flow is shown in fig. 1, and includes: establishing a three-dimensional geometric model, meshing, establishing a temperature field finite element model, solving, and establishing a static analysis finite element model and solving, wherein the method comprises the following steps of:
step 1: establishing a three-dimensional geometric model;
(1) Respectively establishing three-dimensional geometric models of the roller, the matrix and each cladding layer by utilizing three-dimensional modeling software Creo, and assembling the three-dimensional geometric models into an assembly; 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 7mm; the matrix is cuboid, and the length, width and height of the matrix are 100mm, 35mm and 10mm respectively; the length, width and layer height of the cladding layer are respectively 90mm, 4.5mm and 2mm, and the cladding layer totally comprises 7 cladding layers and 7 rollers, as shown in figure 2;
(2) The assembly is output as a file in stp format, named Assemble.
Step two: dividing grids;
(1) Importing a file in a stp format into Hypermesh grid division software, geometrically cleaning a three-dimensional assembly model, deleting and merging redundant points, lines and planes in the three-dimensional assembly;
(2) As shown in fig. 3 and 4, each cladding layer is divided into hexahedral grids, the grid size along the length direction of the cladding layer is 1/3 of the length of the cladding layer deposited in 1 second, the specific size is 1mm, the grid sizes in the thickness and width directions of the cladding layer are respectively 1mm and 0.8mm, and corresponding volume grid sets are created for each unit of the cladding layer, and are sequentially named as: w (W) 1 、W 2 、W 3 、……，W 7 ；
(3) As shown in fig. 3 and 4, 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 which are adjacent to the cladding layer area and far from the cladding layer area along the length and width directions, grids of the adjacent cladding layer area are arranged relatively finely, the grid size is 1.2mm×1.4mm×1mm, grids of the adjacent cladding layer area are arranged sparsely, the grid size is 2.8mm×1.5mm×1mm, the grid nodes which are adjacent to the cladding layer area and far from the cladding layer area are ensured to be continuous in a grid transition mode, and the substrate grids are arranged in a grid set substrate;
(4) Merging and deleting repeated nodes and grids, and outputting the divided grids as an inp file, wherein the name is an assembly.
Step 3: establishing a temperature field finite element model;
(1) Importing the T-assembly file into Abaqus software, and naming the generated model as Temp;
(2) Definition of Boltzmann constant 5.67×10 -8 Absolute zero-273K, unit type DC3D8;
(3) The thermal physical performance parameters of the substrate and the cladding layer with temperature change are defined, and specific parameters are cited by Wenchun Jiang, yucai Zhang, wanchuck Woo.use heat sink technology to decrease residual stress in 316L stainless steel welding joint:Finite element simulation[J ]. International Journal of Pressure Vessels and Piping,2012,92:56-62.
(4) Establishing a thermal 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 number of analysis steps of each cladding layer is N k Equal to the length L of the cladding layer k Divided by cladding layer velocity V k After the last analysis step of each cladding layer, a roll motion analysis step and a cooling analysis step are created, and the total number of analysis steps is created, wherein N=1+2i+N 1 +N 2 +N 3 +……+N i ；
(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, wherein the unit sets of the cladding layers Wk are sequentially named as W-k_1 and W-k_ … … W-k_j (wherein W-k is the name of the corresponding cladding layer and j is the j-th unit set of the cladding layer);
(6) The units of the deposited layer in analysis step 1 are all killed, 2k+N 1 +N 2 +……+N k-1 Sequentially activating the cladding layer N from each analysis step k 1 unit set is activated in each analysis step, and no unit changes in the roll motion analysis step and the cooling analysis step;
(7) Setting initial temperature 293K for all grids;
(8) With airThe contact surfaces are convection and radiation surfaces, and the convection coefficient is 15W/m 2 Emissivity 0.7, ambient temperature 293K;
(9) Setting self-defined heat flux density of the body for all grids, wherein the amplitude is 1;
(10) A double-ellipsoid heat source program is written by utilizing Fortran language, the deposition speed is along the positive direction of the 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 axis is obtained f (x, y, Z), heat flux density q in negative Z-axis direction r (x, y, z) are calculated according to formulas (1) and (2) respectively;
Figure BDA0002968414190000101
Figure BDA0002968414190000102
wherein q is r (x, y, Z) -heat flux density in positive Z-axis direction, q f (x, y, Z) -Z-axis negative heat flux density, Q-arc thermal power, f f 、f r -heat flux density distribution coefficient, x 0 ,y 0 ,z 0 -coordinates at the start of the welding gun, a f 、a r B, c-heat flux density shape parameters;
Q＝UIη
wherein U-welding voltage, I-welding current, eta-thermal efficiency;
(11) Creating a temperature field job file, selecting a heat source program written in Fortran language at a user-defined file, exchanging the job file, and solving to obtain the temperature field, wherein the temperature field is shown in fig. 6, 7 and 8.
Step 4: establishing a static analysis finite element model;
(1) Importing the S-assembly file into Abaqus software, and naming the generated model as Stress;
(2) Defining the unit types of the roller, the cladding layer and the substrate as C3D8R;
(3) Defining thermal expansion coefficient and elastic-plastic parameter of cladding layer and substrate near the cladding layerThe coefficient of thermal expansion and the elastic parameter of the substrate far from the cladding layer region are cited in Wenchun Jiang, yucai Zhang, wanchuck Woo.using heat sink technology to decrease residual stress in 316L stainless steel welding joint:Finite element simulation[J]International Journal of Pressure Vessels and Piping,2012,92:56-62; defining the modulus of elasticity of the roll to be 1000GPa, the Poisson's ratio to be 0.3 and the density to be 7800kg/m 3 ；
(4) Establishing a static force field analysis step, wherein the time corresponding to each static force analysis step is the same as that of a 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 number of analysis steps of each cladding layer is N k Equal to the length L of the cladding layer k Divided by cladding layer velocity V k After the last analysis step of each cladding layer, a roll motion analysis step and a cooling analysis step are created, and the total number of analysis steps is created, wherein N=1+2i+N 1 +N 2 +N 3 +……+N i ；
(5) Sequentially creating unit sets along the length direction of each cladding layer by taking the size of the cladding layer deposited for 1 second as the length, wherein the unit sets of the cladding layers Wk are sequentially named as W-k_1 and W-k_ … … 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 2k+N1+N2+ … … +Nk-1 analysis steps start to activate the unit set of the cladding layer Nk successively, each analysis step activates 1 unit set, and the roller motion analysis step and the cooling analysis step have no unit death change;
(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 be used as a load calculated by the stress field;
(8) Defining an initial temperature, wherein the value of the initial temperature is set to be the ambient temperature 293K;
(9) Respectively by rollers Z k 2 reference points are established by taking the circle center of the end surface as a reference, are named as RP-k and MRP-k, and a local coordinate Csys-k, in which each coordinate axis is parallel to the global coordinate axis, is established by taking the RP-k as the origin of coordinates;
(10) Will beRoller Z k Is coupled with a reference point RP-k, thereby establishing a rigid body constraint;
(11) Taking a reference point MRP-k as a control point, establishing the reference point MRP-k and the reference point RP-k as motion coupling constraints, and coupling translational motions of the two reference points in the X, Y, Z direction;
(12) 2k+N 1 +N 2 +……+N k-1 The analysis step starts, and the roller Z corresponding to the kth cladding layer k Starting the movement, setting the speed of the reference point MRP-k in the X, Y, Z direction under the global coordinate to ensure 2k+N 1 +N 2 +……+N k-1 At the end of the analysis steps, roll Z k The cladding layer is rolled and pressed at the beginning, and the 1+2k+N is modified 1 +N 2 +……+N k-1 The speed of each analysis step was set to V in the longitudinal direction of the cladding layer k The speed in the width and thickness directions of the cladding layer was 0, and was 2k+N 1 +N 2 +……+N k The analysis step does not function with this boundary condition;
(13) 2k+N 1 +N 2 +……+N k-1 Starting with the analysis step, a reference point RP-k is set at a local coordinate Csys-k around the roll Z k The rotation speed of the coordinate axes with the coincident axes is from 2k+N 1 +N 2 +……+N k The analysis step does not function with this boundary condition;
(14) According to the actual situation, adding mechanical constraint conditions to the matrix to avoid rigid motion of the model;
(15) Static analysis job is created and submitted for solution, the simulated deformations are shown in fig. 9-14, and the simulated residual stresses are shown in fig. 15-18.
The invention provides a numerical simulation modeling method for residual stress and deformation of a TIG (tungsten inert gas) additive and rolling composite manufacturing 316L stainless steel part, which can realize solving and predicting of a temperature field, residual stress and deformation evolution rule in the TIG additive and rolling composite manufacturing process and has application potential in the aspects of TIG additive and rolling composite manufacturing mechanism research and engineering process parameter formulation.

Claims (3)

1. A method of predicting TIG additive and rolling composite fabrication residual stress and deformation comprising the steps of;
step one: establishing a three-dimensional geometric model by using Creo software;
(1) Respectively establishing three-dimensional geometric models of the roller, the matrix and each cladding layer, establishing a roller matched with each cladding layer, and assembling the roller, the matrix and the cladding layers into an assembly;
(2) Outputting the assembly as a file in the stp format, wherein the name is an assembly;
step two: dividing grids by Hypermesh software;
(1) Importing a file in a stp format into Hypermesh grid division software, geometrically cleaning a three-dimensional assembly model, deleting and merging redundant points, lines and surfaces in the assembly model;
(2) Dividing each cladding layer into hexahedral grids, wherein the grid size along the length direction of the cladding layer is 1/3 of the length of the cladding layer deposited in 1 second, and creating a corresponding volume grid set for each cladding layer unit, which is sequentially named as: w (W) 1 、W 2 、W 3 、……，W k K is the number of cladding layers;
(3) Dividing a substrate into two parts, namely a nearby cladding layer area and a far cladding layer area, along the length and width directions by taking the width of the cladding layer which is 1.5 times from the edge of the cladding layer as a boundary line, arranging grids in the nearby cladding layer area in a relatively fine manner, arranging grids in the far cladding layer area in a sparse manner, ensuring that nodes in the nearby cladding layer area and the far cladding layer area are continuous in a grid transition manner, and arranging the grids of the substrate in a grid set substrate;
(4) Dividing each roller into hexahedral meshes, and sequentially placing the hexahedral meshes in a mesh set Z 1 、Z 2 、Z 3 、……，Z k In, k is the number of cladding layers;
(5) Merging and deleting repeated nodes and grids, and outputting grids of a matrix and a cladding layer as an inp file, which is named as T-assembly, and outputting all grids as an inp file, which is named as S-assembly;
step three: establishing a temperature field finite element model and solving based on Abaqus software;
(1) Importing the T-assembly 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 the thermophysical performance parameters of the substrate and the cladding layer along with the temperature change;
(4) Establishing a thermal 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 number of analysis steps of each cladding layer is N k Equal to the length L of the cladding layer k Divided by cladding layer velocity V k After the last analysis step of each cladding layer, a roll motion analysis step and a cooling analysis step are created, and the total number of analysis steps is created, wherein N=1+2i+N 1 +N 2 +N 3 +……+N i ；
(5) With a size of 1 time of welding speed as a length, a unit set is sequentially created along the length direction of each cladding layer, and the cladding layers W k The unit sets are named W-k_1, W-k_ … … W-k_j in sequence, where j is the cladding layer W k Is the j-th set of cells;
(6) The units of the deposited layer in analysis step 1 are all killed, 2k+N 1 +N 2 +……+N k-1 Sequentially activating the cladding layer N from each analysis step k 1 unit set is activated in each analysis step, and no unit changes in the roll motion analysis step and the cooling analysis step;
(7) Setting initial temperature 293K for all grids;
(8) Setting self-defined heat flux density of the body for all grids, wherein the amplitude is 1;
(9) The surfaces contacted with the air are all convection and radiation surfaces, and the convection coefficient is 15W/m 2 Emissivity 0.7, ambient temperature 293K;
(10) Creating a job file, selecting a storage path corresponding to a heat flow program, submitting the job file, and solving to obtain a cladding process and a temperature field after cooling is finished;
step four: establishing a static analysis finite element model and solving based on Abaqus software;
(1) Importing the S-assembly file into Abaqus software, and naming the generated model as Stress;
(2) Defining the unit type of the cladding layer and the matrix;
(3) Defining a cladding layer, a region close to the cladding layer and a thermal expansion coefficient far away from the cladding layer, endowing elastic-plastic performance parameters to the cladding layer and the region close to the cladding layer, endowing elastic performance parameters only to materials far away from the cladding layer, and defining elastic parameters and density of a roller;
(4) Establishing a static force field analysis step, wherein the time corresponding to each static force analysis step is the same as that of a 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 number of analysis steps of each cladding layer is N k Equal to the length L of the cladding layer k Divided by cladding layer velocity V k After the last analysis step of each cladding layer, a roll motion analysis step and a cooling analysis step are created, and the total number of analysis steps is created, wherein N=1+2i+N 1 +N 2 +N 3 +……+N i ；
(5) The size of the cladding layer deposited for 1 second is taken as the length, a unit set is sequentially created along the length direction of each cladding layer, and the cladding layers W k The unit sets are named W-k_1, W-k_ … … W-k_j in sequence, where j is the cladding layer W k Is the j-th set of cells;
(6) The units of the deposited layer in analysis step 1 are all killed, 2k+N 1 +N 2 +……+N k-1 Sequentially activating the cladding layer N from each analysis step k 1 unit set is activated in each analysis step, and no unit changes in the roll motion 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 stress field calculation result as a stress field calculation load;
(8) Defining an initial temperature, wherein the value of the initial temperature is set to be the ambient temperature 293K;
(9) Respectively by rollers Z k Establishing 2 reference points with the center of the end face as a reference, naming A, B, and establishing each point by taking A as the origin of coordinatesA local coordinate C with a coordinate axis parallel to the global coordinate axis;
(10) Roll Z k Is coupled to reference point a, thereby establishing a rigid body constraint;
(11) Taking the reference point B as a control point, establishing the reference point B and the reference point A as motion coupling constraint, and coupling translational motions of the two reference points in the X, Y, Z direction;
(12) 2k+N 1 +N 2 +……+N k-1 The analysis step starts, and the roller Z corresponding to the kth cladding layer k Starting the movement, setting the speed of the reference point B in the X, Y, Z direction under the global coordinate to ensure 2k+N 1 +N 2 +……+N k-1 At the end of the analysis steps, roll Z k The cladding layer is rolled and pressed at the beginning, and the 1+2k+N is modified 1 +N 2 +……+N k-1 The speed of each analysis step was set to V in the longitudinal direction of the cladding layer k The speed in the width and thickness directions of the cladding layer was 0, and was 2k+N 1 +N 2 +……+N k The analysis step does not function with this boundary condition;
(13) 2k+N 1 +N 2 +……+N k-1 The analysis steps are started, and a reference point A is set at a local coordinate C and is wound around a roller Z k The rotation speed of the coordinate axes with the coincident axes is from 2k+N 1 +N 2 +……+N k The analysis step does not function with this boundary condition;
(14) According to the actual situation, mechanical constraint conditions are added to the matrix, so that the matrix is prevented from rigid motion;
(15) And creating a static force analysis job, submitting the static force analysis job to solve the static force analysis job, and obtaining residual stress and deformation distribution after the cladding process and cooling are finished.
2. The method for predicting residual stress and deformation of a TIG additive and rolling composite manufacturing part according to claim 1, wherein a roller matched with each cladding layer is established, and the problem that a static analysis finite element model is difficult to converge is solved.
3. The method for predicting residual stress and deformation of a TIG additive and rolling composite manufacturing part according to claim 1, wherein in the grid division process, a substrate is divided into two parts, namely a nearby cladding layer area and a far cladding layer area by taking the width of the cladding layer which is 1.5 times as large as the edge of the cladding layer as a boundary line, grids of the nearby cladding layer area are arranged relatively densely, grids of the far cladding layer area are arranged sparsely, a grid transition mode is adopted to ensure that grid nodes of the nearby cladding layer area and the far cladding layer area are continuous, and calculation time is saved on the premise that solving accuracy is not affected.
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