CN113283139A - ANSYS-based SLM single-channel multilayer scanning forming numerical simulation method - Google Patents

ANSYS-based SLM single-channel multilayer scanning forming numerical simulation method Download PDF

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CN113283139A
CN113283139A CN202110583751.0A CN202110583751A CN113283139A CN 113283139 A CN113283139 A CN 113283139A CN 202110583751 A CN202110583751 A CN 202110583751A CN 113283139 A CN113283139 A CN 113283139A
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ansys
heat source
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laser
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杨鑫
王风辉
孙晨皞
赖杨凯
张兆洋
王犇
王婉琳
马文君
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Xian University of Technology
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Abstract

The invention discloses an SLM single-channel multilayer scanning forming numerical simulation method based on ANSYS.A single-channel multilayer scanning process of laser additive manufacturing is simulated by combining an ANSYS classic version and a WORKBENCH module, different heat sources are applied to each layer by taking time as a node, meanwhile, the continuity of heat source movement is also ensured, and a set piecewise function is led into an editor and a command stream is led out through an ANSYS function editor, so that the layer-by-layer movement of the heat source is realized; by adopting the simulation method, the temperature history of the forming process of the workpiece and the relation between layers can be analyzed, and the temperature field, the temperature history and the stress field change under different parameters can be analyzed by adjusting the parameters, so that theoretical support is provided for actual printing.

Description

ANSYS-based SLM single-channel multilayer scanning forming numerical simulation method
Technical Field
The invention belongs to the technical field of numerical simulation of additive manufacturing computers, and particularly relates to an SLM single-pass multilayer scanning forming numerical simulation method based on ANSYS.
Background
The laser additive manufacturing is an unstable, extremely cold and extremely hot transient process, local heat input in the manufacturing accumulation process necessarily causes uneven temperature fields, and the local heat effect is directly shown as that a molten pool is easy to form residual stress in the solidification and subsequent cooling processes. The residual stress is used as an internal stress, which directly influences the static load strength, fatigue strength, stress corrosion resistance and other properties of a formed part and the stability of the size, and when the residual stress is serious, crack defects are directly caused.
With the continuous development of computer technology, the computer is also receiving more and more attention for simulation. Through computer simulation, the distribution change of temperature stress in the SLM forming process, such as temperature distribution, molten pool size, thermal stress distribution and the like in the machining process can be visually seen. These parameters have important reference function for researching microstructure change of material, internal defect formation and the like.
Disclosure of Invention
The invention aims to provide an SLM single-pass multi-layer scanning forming numerical simulation method based on ANSYS, which is used for realizing the movement of a heat source among multiple layers in the laser additive manufacturing numerical simulation process.
The invention adopts the technical scheme that an SLM single-channel multilayer scanning forming numerical simulation method based on ANSYS is implemented according to the following steps:
step 1, establishing a numerical simulation model, and establishing a three-dimensional model required by simulation through three-dimensional modeling software, wherein the model comprises a basal layer and a powder layer;
step 2, newly building an additive manufacturing numerical simulation task, and creating a new simulation task by a heat-force coupling module in the additive manufacturing process in WORKBENCH;
step 3, adding materials, namely adding materials required by laser additive manufacturing simulation in WORKBENCH, wherein the materials comprise a base material and a powder layer material;
step 4, importing a model, opening a model option in a flow chart of thermal analysis, and importing the three-dimensional model established in the step 1;
step 5, respectively endowing the powder layer and the substrate layer with corresponding materials based on the materials added in the step 3;
step 6, dividing grids;
step 7, adding heat transfer, and setting convection heat transfer between the powder and the substrate;
step 8, adding a living and dead unit, realizing the conversion of solid powder, fluid and solid by adopting a living and dead unit technology, adding the living and dead unit, endowing each unit body with the living and dead unit, and setting the living and dead of the unit;
step 9, setting the number of steps, and setting the time for the laser to sweep each life and death unit according to the size and the scanning speed of the life and death unit, wherein each life and death unit is equivalent to one step;
step 10, adding a heat source, and simulating a laser additive manufacturing process based on finite element software, wherein the type of the heat source is selected to be a Gaussian heat source;
and 11, calculating and solving, and selecting the temperature to solve.
The invention is also characterized in that:
the powder layers created in the step 1 are stacked in hexahedral units, and then grid division is carried out, wherein the base layer and the powder layers are integrated;
wherein the powder layer in the step 1 is a single-channel multilayer;
wherein the grid divided in the step 6 uses a Cartesian grid with voxelization options, and the grid of the basal layer is larger than the grid of the powder layer;
setting each layer of powder as a life-death unit in the step 8, selecting each layer one by one, and creating naming selection for the selected geometric entities for subsequent heat source loading;
wherein the Gaussian heat source in the step 10 comprises the following steps: the simulation strategy is a single-channel multilayer, and the Gaussian surface heat source and the Gaussian body heat source are adopted:
Figure BDA0003087252300000031
in the formula, Q is heat flux density, A is laser utilization rate, P is laser power, R is laser spot radius, and x and y are coordinate axes with the center of a laser spot as an origin;
in step 10, the heat source moves from the first layer to the upper layer by layer, each layer is a separate function, where the variable is the scan time, and thus the function can be defined as:
layer 1:
Figure BDA0003087252300000032
layer 2:
Figure BDA0003087252300000033
Figure BDA0003087252300000034
an nth layer:
Figure BDA0003087252300000035
wherein Q is heat flux density, A is laser utilization rate, P is laser power, R is laser spot radius, T is time, x, y are coordinate axes with the laser spot center as origin, and T isn-1Sum of time for scanning n-1 layers for the laser；
In the ANSYS classic version, a function editor is used to add a plurality of functions, the command stream is read and exported after being stored, and the command stream is added to an ANSYS-WORKBENCH, and the heat source is applied.
The invention has the beneficial effects that:
the SLM single-channel multilayer scanning forming numerical simulation method based on ANSYS can indirectly obtain the temperature field and the stress field through numerical simulation of a laser additive manufacturing multilayer scanning process, can exchange different parameters to carry out a numerical model, and obtains the temperature field and the stress field under different parameters, particularly: the temperature history between each layer can be obtained, the influence between layers is further analyzed, the optimal printing parameters are obtained by analyzing the temperature history and the change of a stress field, and the method has guiding significance for actual engineering.
Drawings
FIG. 1 is a flow chart of an SLM single-pass multi-layer scanning forming numerical simulation method based on ANSYS according to the present invention;
fig. 2 is a model diagram of a laser additive manufacturing multi-channel scanning numerical simulation method based on ANSYS according to the present invention;
fig. 3 is a result chart of an embodiment of the SLM single-pass multi-layer scan forming numerical simulation method based on ANSYS of the present invention.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
The invention provides an SLM single-channel multilayer scanning forming numerical simulation method based on ANSYS, which is implemented by the following steps as shown in figure 1:
step 1, establishing a numerical simulation model, establishing a three-dimensional model required by simulation through three-dimensional modeling software, wherein the model comprises a base layer and a powder layer, the established powder layer is stacked in hexahedral units, subsequently, gridding is carried out, and the base layer and the powder layer are integrated in order to ensure that gridding is continuous;
step 2, newly building an additive manufacturing numerical simulation task, and creating a new simulation task by a heat-force coupling module in the additive manufacturing process in WORKBENCH;
step 3, adding materials, namely adding materials required by laser additive manufacturing simulation in WORKBENCH, wherein the materials comprise a base material and a powder layer material;
step 4, importing a model, opening a model option in a flow chart of thermal analysis, and importing the three-dimensional model established in the step 1;
step 5, respectively endowing the powder layer and the substrate layer with corresponding materials based on the materials added in the step 3;
step 6, dividing grids, wherein the divided grids use Cartesian grids with voxelization options, and the grid of the basal layer is larger than the grid of the powder layer;
step 7, adding heat transfer, and setting convection heat transfer between the powder and the substrate;
step 8, adding a living and dead unit, realizing the conversion of solid powder, fluid and solid by adopting a living and dead unit technology, adding the living and dead unit, endowing each unit body with the living and dead unit, and setting the living and dead of the unit;
step 9, setting the number of steps, and setting the time for the laser to sweep each life and death unit according to the size and the scanning speed of the life and death unit, wherein each life and death unit is equivalent to one step;
step 10, adding a heat source, and simulating a laser additive manufacturing process based on finite element software, wherein the type of the heat source is selected to be a Gaussian heat source; the Gaussian heat source comprises: gaussian surface heat source, Gaussian body heat source, adopting Gaussian surface heat source:
Figure BDA0003087252300000051
in the formula, Q is the heat flux density, a is the laser utilization rate, P is the laser power, R is the laser spot radius, and x, y are coordinate axes with the laser spot center as the origin.
The moving mode of the heat source moves from the first layer to the upper layer by layer, and since the scanning process is scanning layer by layer, the loading of the moving heat source cannot use a single function, each layer is a separate function, wherein the variable is the scanning time, and therefore the function can be defined as:
layer 1:
Figure BDA0003087252300000061
layer 2:
Figure BDA0003087252300000062
Figure BDA0003087252300000063
an nth layer:
Figure BDA0003087252300000064
wherein Q is heat flux density, A is laser utilization rate, P is laser power, R is laser spot radius, T is time, x, y are coordinate axes with the laser spot center as origin, and T isn-1-is the sum of the time the laser sweeps through n-1 layers;
in the ANSYS classic version, a function editor is adopted to add a single function, the command stream is read and derived after storage, the single function is added into ANSYS-WORKBENCH one by one (the command stream derived from the function of the corresponding layer is added into the layer), and the heat source application is finished;
step 11, calculating and solving, and selecting temperature to solve;
as shown in fig. 2, based on the above method, the SLM is simulated to form 316L stainless steel, in order to save the calculation time, a smaller model is used for simulation, the size of the substrate layer is 6mm × 8mm × 2mm, the single layer of the powder layer is 0.35mm × 0.35mm × 2.8mm, 3 layers are arranged, the laser utilization rate is 0.35, the laser power is 120W, the scanning rate is 700mm/s, and the heat source function:
Figure BDA0003087252300000071
layer 1:
Figure BDA0003087252300000072
layer 2:
Figure BDA0003087252300000073
layer 3:
Figure BDA0003087252300000074
inputting the functions into an AYYS function editor, deriving a command stream and applying the command stream to a model; the results are shown in FIG. 3.

Claims (7)

1. The SLM single-channel multilayer scanning forming numerical simulation method based on ANSYS is characterized by comprising the following steps:
step 1, establishing a numerical simulation model, and establishing a three-dimensional model required by simulation through three-dimensional modeling software, wherein the model comprises a basal layer and a powder layer;
step 2, newly building an additive manufacturing numerical simulation task, and creating a new simulation task by a heat-force coupling module in the additive manufacturing process in WORKBENCH;
step 3, adding materials, namely adding materials required by laser additive manufacturing simulation in WORKBENCH, wherein the materials comprise a base material and a powder layer material;
step 4, importing a model, opening a model option in a flow chart of thermal analysis, and importing the three-dimensional model established in the step 1;
step 5, respectively endowing the powder layer and the substrate layer with corresponding materials based on the materials added in the step 3;
step 6, dividing grids;
step 7, adding heat transfer, and setting convection heat transfer between the powder and the substrate;
step 8, adding a living and dead unit, realizing the conversion of solid powder, fluid and solid by adopting a living and dead unit technology, adding the living and dead unit, endowing each unit body with the living and dead unit, and setting the living and dead of the unit;
step 9, setting the number of steps, and setting the time for the laser to sweep each life and death unit according to the size and the scanning speed of the life and death unit, wherein each life and death unit is equivalent to one step;
step 10, adding a heat source, and simulating a laser additive manufacturing process based on finite element software, wherein the type of the heat source is selected to be a Gaussian heat source;
and 11, calculating and solving, and selecting the temperature to solve.
2. An ANSYS-based SLM single pass multi-layer scan shaping numerical simulation method according to claim 1, characterized in that the powder layers created in step 1 are stacked in hexahedral cells, followed by gridding, the base layer and the powder layers being one whole.
3. An ANSYS-based SLM single-pass multi-layer scan shaping numerical simulation method according to claim 1, wherein the powder layer in step 1 is a single-pass multi-layer.
4. An ANSYS-based SLM single pass multi-slice scan shaping numerical simulation method of claim 1 wherein the grid divided in step 6 uses a Cartesian grid with voxelization options and the base layer grid is larger than the powder bed grid.
5. An ANSYS-based SLM single-pass multi-layer scanning modeling numerical simulation method according to claim 1, characterized in that in step 8 each layer of powder is set as a life-dead unit, and each layer is selected one by one to respectively create naming selection for the selected geometric entities for subsequent heat source loading.
6. An ANSYS-based SLM single pass multi layer scan shaping numerical simulation method according to claim 1, wherein the gaussian heat source in step 10 is divided into: the simulation strategy is a single-channel multilayer, and the Gaussian surface heat source and the Gaussian body heat source are adopted:
Figure FDA0003087252290000021
in the formula, Q is the heat flux density, a is the laser utilization rate, P is the laser power, R is the laser spot radius, and x, y are coordinate axes with the laser spot center as the origin.
7. An ANSYS-based SLM single pass multi layer scan shaping numerical simulation method according to claim 1, wherein the heat source is moved from the first layer up layer by layer in step 10, each layer being a separate function, wherein the variable is the scan time, and thus the function can be defined as:
layer 1:
Figure FDA0003087252290000031
layer 2:
Figure FDA0003087252290000032
.
.
an nth layer:
Figure FDA0003087252290000033
wherein Q is heat flux density, A is laser utilization rate, P is laser power, R is laser spot radius, T is time, x, y are coordinate axes with the laser spot center as origin, and T isn-1-is the sum of the time the laser sweeps through n-1 layers;
in the ANSYS classic version, a function editor is used to add a plurality of functions, the command stream is read and exported after being stored, and the command stream is added to an ANSYS-WORKBENCH, and the heat source is applied.
CN202110583751.0A 2021-05-27 2021-05-27 ANSYS-based SLM single-channel multilayer scanning forming numerical simulation method Pending CN113283139A (en)

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