CN113343521A - Method for predicting interlayer thermal stress distribution in selective laser melting process based on COMSOL - Google Patents
Method for predicting interlayer thermal stress distribution in selective laser melting process based on COMSOL Download PDFInfo
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Abstract
The application provides a method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL, which comprises the following steps: s1: constructing a three-dimensional solid heat transfer and structural mechanics transient model based on COMSOL; s2: determining parameters in the simulation process; s3: determining a material property of the powder to be melted; s4: determining a moving Gaussian heat source parameter; s5: constructing a geometric model of the powder bed; s6: realizing the layer-by-layer manufacturing of selective laser melting; s7: grid division and node temperature calculation; s8: the interlayer thermal stress distribution and the residual thermal stress distribution are predicted from the result of step S7. The method simulates the laser heat source effect in the processing process through a moving Gaussian heat source die, and replaces a powder bed with a uniform material powder bed; in addition, the structural mechanics module is used for simulating the thermal stress generated by the layer and the deformation condition of a workpiece when the layer moves along with a heat source, and simulating the layer-by-layer manufacturing process of the selective laser melting technology, so that the prediction of the thermal stress and the residual thermal stress among multiple layers is realized.
Description
Technical Field
The invention relates to the technical field of thermal stress distribution, in particular to a method for predicting interlayer thermal stress distribution in a selective laser melting technology based on COMSOL.
Background
The selective laser melting technology is a near-net-shape forming technology for manufacturing solid parts based on a material discrete-gradual accumulation mode. The technology generally takes metal powder as a raw material, sets a laser scanning path through three-dimensional model pre-layering treatment, and adopts a high-energy laser beam to melt the metal powder layer by layer according to the set scanning path, so that the metal powder is rapidly solidified and accumulated to form a high-performance component. In the laser melting technique, the metal material undergoes rapid heating, solidification, and cooling processes, in which large thermal stresses and structural stresses caused by solid-state phase transformation are formed. These stresses remain inside the workpiece after the forming is completed, and become residual stresses. If the residual stress exceeds the yield strength of the material itself, the formed article is deformed, resulting in a reduction in dimensional accuracy and in workability. Therefore, the deformation of the metal parts manufactured by the additive is one of the research hotspots in the field of the additive manufacturing at home and abroad. The existing method for predicting interlayer thermal stress in the manufacturing process of the laser melting technology is a volume heat source method, namely, a slice entity is generated in each layer and is provided with a volume heat source, so that distribution of interlayer thermal stress is predicted, for example, an existing ANSYS newly-added additive manufacturing plate is used. However, when the volume heat source is loaded on each sliced layer, only the distribution of the thermal stress between layers can be predicted, and the distribution of the thermal stress accumulated in a single scanning on each layer cannot be accurately predicted.
Therefore, a method for accurately predicting the cumulative thermal stress of a single scan on each layer is needed.
Disclosure of Invention
In view of the above, the present invention provides a method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL, which is characterized in that: the method comprises the following steps:
s1: constructing a three-dimensional solid heat transfer and structural mechanics transient model based on COMSOL;
s2: determining parameters in a simulation process, wherein the parameters comprise a scanning interval D _ spot, a laser scanning speed v _ spot, laser power P _ laser, a laser radius r _ spot, a surface radiance A _ Gass, a powder accumulation rate w _ powder and a powder layer thickness;
s3: determining material properties of the powder to be melted, the material properties including thermal conductivity, specific heat capacity, material density, thermal expansion coefficient, Young's modulus, and Poisson's ratio;
s4: determining mobile Gaussian heat source parameters, wherein the mobile Gaussian heat source parameters comprise the number of mobile Gaussian heat sources and a difference function related to time used by each mobile Gaussian heat source;
s5: constructing a geometric model of the powder bed, and determining initial conditions, boundary heat source conditions and boundary conditions of the geometric model of the powder bed under solid mechanical nodes;
s6: realizing the layer-by-layer manufacturing of selective laser melting;
s7: carrying out mesh division on the geometric model of the powder bed and determining the temperature, stress and strain of a node; the temperature, stress and strain of the node are determined by energy conservation and stress balance through meshing.
S8: the interlayer thermal stress distribution and the residual thermal stress distribution are predicted from the result of step S7.
Further, step S3 includes a step of preprocessing the shape of the powder material to be melted stacked on the powder bed, that is, preprocessing the apparent density of the powder, the preprocessing being for approximating the powder bed of the powder stacked as a rectangular parallelepiped.
Further, the value range of the powder apparent density is 40-60%.
Further, the powder bulk density was 50%.
Further, the number of the gaussian heat sources to be moved in step S4 is determined according to the slice shape, the scanning pitch, and the laser radius, so that one tiling scan thereof can cover the target slice shape.
Further, the difference function in step S4 is determined by the following method:
x_focus＝x_f1(t) (1)
wherein x represents the x direction of movement of the gaussian heat source, x _ focus represents the focus of the x to the gaussian heat source, and x _ f1(t) represents a function of the x direction of movement of the gaussian heat source;
y_focus＝y_f1(t) (2)
wherein y represents the y direction of movement of the gaussian heat source, y _ focus represents the focus of the y-direction gaussian heat source, and y _ f1(t) represents a function of the y direction of movement of the gaussian heat source;
r_focus＝sqrt((x-x_focus)∧2+(y-y_focus)∧2) (3)
wherein r _ focus represents a focus of the gaussian heat source, the focus is determined by a focus of the gaussian heat source in x direction and y direction, x represents an x direction of movement of the gaussian heat source, x _ focus represents a focus of the gaussian heat source in x direction, y represents a y direction of movement of the gaussian heat source, and y _ focus represents a focus of the gaussian heat source in y direction;
Flux＝((2*A_Gass*P_laser)/(pi*r_spot∧2))*exp(-2*r_focus∧2)/r_spot∧2)(4)
wherein Flux represents the heat Flux of a Gaussian heat source, A _ Gass represents the absorptivity of a material, P _ laser represents a laser heat source, pi represents pi, r _ spot represents the laser radius, and r _ focus represents the focal point of the Gaussian heat source.
The invention has the beneficial technical effects that: the method simulates the laser heat source effect in the processing process by considering the phase change of the material and the influence of the thermal radiation and natural convection on the surface of the material on the temperature field through a moving Gaussian heat source die, and replaces a powder bed with a uniform material powder bed by carrying out approximate treatment on the material property; in addition, the structural mechanics module is used for simulating the thermal stress generated by the layer and the deformation condition of a workpiece when the layer moves along with a heat source, and finally, the process of manufacturing layer by the selective laser melting technology is simulated by using an activation method, so that the prediction of the thermal stress and residual thermal stress among multiple layers and the influence of the laser action effect of a rear layer on a front layer are realized.
Drawings
The invention is further described below with reference to the following figures and examples:
fig. 1 is a flow chart of the present application.
Fig. 2 is a grid split view of the present application.
Fig. 3 is a schematic diagram of the temperature field and stress field of the present application.
Detailed Description
The invention is further described with reference to the accompanying drawings in which:
the invention provides a method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL, which is characterized by comprising the following steps of: the method comprises the following steps: as shown in figure 1 of the drawings, in which,
s1: constructing a three-dimensional solid heat transfer and structural mechanics transient model based on COMSOL;
s2: determining parameters in a simulation process, wherein the parameters comprise a scanning interval D _ spot, a laser scanning speed v _ spot, laser power P _ laser, a laser radius r _ spot, a surface radiance A _ Gass, a powder accumulation rate w _ powder and a powder layer thickness;
s3: determining material properties of the powder to be melted, the material properties including thermal conductivity, specific heat capacity, material density, thermal expansion coefficient, Young's modulus, and Poisson's ratio;
s4: determining mobile Gaussian heat source parameters, wherein the mobile Gaussian heat source parameters comprise the number of mobile Gaussian heat sources and a difference function related to time used by each mobile Gaussian heat source;
s5: constructing a geometric model of the powder bed, and determining initial conditions, boundary heat source conditions and boundary conditions of the geometric model of the powder bed under solid mechanical nodes;
the initial conditions of the geometric model, the boundary heat source conditions and the boundary conditions under the determined solid mechanical nodes are as follows:
solid heat transfer
1. To simulate the substrate pre-heating effect, all initial temperatures were defined as 35degC, all surfaces of the model were defined as a heat transfer coefficient of 80W/(m 2K), and the boundary conditions for convective heat flux simulate the effect of the wind field on the process during processing.
2. Secondly, the material surface acted by laser is defined as the boundary condition of the surface to the environmental radiation, and the heat exchange process of the high-temperature material surface and the environment under the action of a moving Gaussian heat source is simulated.
3. Next, a time dependent gaussian heat source is defined for each layer material to simulate the loading of the heat source.
Mechanics of solids
1. A fixed constraint boundary condition is imposed on the bottom surface of the substrate to prevent deformation in this direction.
2. Adding a thermal expansion node to the material being lased.
3. To achieve layer-by-layer fabrication, a time-dependent activation expression is used with an activation scaling factor set to 1 e-5.
S6: realizing the layer-by-layer manufacturing of selective laser melting; the successive processing of the laser was simulated in three passes for each layer using a "zigzag" scanning strategy, in which the total duration of the laser action for each layer was 0.00116s, and a cooling time of 0.2 x t x was taken into account, before the first next powder bed was activated.
S7: carrying out mesh division on the geometric model of the powder bed and determining the temperature, stress and strain of a node; the temperature, stress and strain of the node are determined by energy conservation and stress balance through meshing. The method is used for modeling, and simple grid division is performed on the model so as to achieve corresponding effects. The lower diagram is a grid split view and the sequence of layer-by-layer fabrication. As shown in fig. 2.
S8: the interlayer thermal stress distribution and the residual thermal stress distribution are predicted from the result of step S7. As shown in fig. 3. Step S8 represents the result from the target physical quantity using the function of "post-processing" of the COMSOL software. Step S7 is to divide the powder bed by finite element, that is, the whole is broken to zero, and the temperature, stress and strain of each node are determined, step S8 is to zero the calculation result of each node to be the whole, and the temperature, stress and strain of the powder bed are obtained by software post-processing function from the whole angle of the powder bed, thereby realizing the prediction of interlayer thermal stress and residual thermal stress. For example, by using stress as an example, a three-dimensional stress viewing node is established under a result node, and a desired result can be obtained by inputting an expression, and the temperature and the strain can be viewed in the same manner, which is not described herein again.
According to the technical scheme, the influence of phase change of the material and the influence of thermal radiation and natural convection on the surface of the material on a temperature field are considered through the moving Gaussian heat source die, the laser heat source effect in the machining process is simulated, the material attribute is approximately treated, and a uniform material powder bed is used for replacing a powder bed; in addition, the structural mechanics module is used for simulating the thermal stress generated by the layer and the deformation condition of a workpiece when the layer moves along with a heat source, and finally, the process of manufacturing layer by the selective laser melting technology is simulated by using an activation method, so that the prediction of the thermal stress and residual thermal stress among multiple layers and the influence of the laser action effect of a rear layer on a front layer are realized.
In this embodiment, step S3 further includes preprocessing the shape of the powder material to be melted stacked on the powder bed, that is, preprocessing the apparent density of the powder, which is used to approximate the powder bed of the powder stacked to a rectangular parallelepiped. Because the method is used for predicting the interlayer thermal stress and cannot represent the physical phenomenon of the melting process, the method predicts the thermal stress by utilizing a more regular powder bed after melting, and the purpose of approximately processing and reducing the calculation difficulty is to regard the powder bed as a regular cuboid.
In this embodiment, the bulk density of the powder ranges from 40% to 60%. The powder had a bulk density of 50%. In the powder bed modeling process, hundreds of powder balls are stacked on the powder bed, pores exist between the powder balls, the loose packed density reflects the porosity of the powder bed, and in the embodiment, the loose packed density is 50% and is used for simulating the powder bed stacking effect.
In this embodiment, the number of gaussian heat sources to be moved in step S4 is determined according to the slice shape, the scanning pitch, and the laser radius, so that one tiling scan thereof can cover the target slice shape. As an example to demonstrate the determination of the number of gaussian heat sources: each layer of powder bed is modeled according to a regular model, the length and the times of Gaussian heat source scanning depend on the shape of each layer of slice, the slice is a regular rectangle, and the regular cuboid in the case can be scanned by three times of scanning under the preset scanning interval and the preset laser radius. One skilled in the art can determine the number of gaussian heat sources based on the actual slices, scan spacing and laser radius.
In the present embodiment, the difference function in step S4 is determined by the following method:
x_focus＝x_f1(t) (1)
wherein x represents the x direction of movement of the gaussian heat source, x _ focus represents the focus of the x to the gaussian heat source, and x _ f1(t) represents a function of the x direction of movement of the gaussian heat source;
y_focus＝y_f1(t) (2)
wherein y represents the y direction of movement of the gaussian heat source, y _ focus represents the focus of the y-direction gaussian heat source, and y _ f1(t) represents a function of the y direction of movement of the gaussian heat source;
r_focus＝sqrt((x-x_focus)∧2+(y-y_focus)∧2) (3)
wherein r _ focus represents a focus of the gaussian heat source, the focus is determined by a focus of the gaussian heat source in x direction and y direction, x represents an x direction of movement of the gaussian heat source, x _ focus represents a focus of the gaussian heat source in x direction, y represents a y direction of movement of the gaussian heat source, and y _ focus represents a focus of the gaussian heat source in y direction;
Flux＝((2*A_Gass*P_laser)/(pi*r_spot∧2))*exp(-2*r_focus∧2)/r_spot∧2)(4)
wherein Flux represents the heat Flux of a Gaussian heat source, A _ Gass represents the absorptivity of a material, P _ laser represents a laser heat source, pi represents pi, r _ spot represents the laser radius, and r _ focus represents the focal point of the Gaussian heat source.
Finally, the above embodiments are only for illustrating the technical solutions of the present invention and not for limiting, although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications or equivalent substitutions may be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all of them should be covered in the claims of the present invention.
Claims (6)
1. A method for predicting interlayer thermal stress distribution in a selective laser melting process based on COMSOL is characterized by comprising the following steps: the method comprises the following steps:
s1: constructing a three-dimensional solid heat transfer and structural mechanics transient model based on COMSOL;
s2: determining parameters in a simulation process, wherein the parameters comprise a scanning interval D _ spot, a laser scanning speed v _ spot, laser power P _ laser, a laser radius r _ spot, a surface radiance A _ Gass, a powder accumulation rate w _ powder and a powder layer thickness;
s3: determining material properties of the powder to be melted, the material properties including thermal conductivity, specific heat capacity, material density, thermal expansion coefficient, Young's modulus, and Poisson's ratio;
s4: determining mobile Gaussian heat source parameters, wherein the mobile Gaussian heat source parameters comprise the number of mobile Gaussian heat sources and a difference function related to time used by each mobile Gaussian heat source;
s5: constructing a geometric model of the powder bed, and determining initial conditions, boundary heat source conditions and boundary conditions of the geometric model of the powder bed under solid mechanical nodes;
s6: realizing the layer-by-layer manufacturing of selective laser melting;
s7: carrying out mesh division on the geometric model of the powder bed and determining the temperature, stress and strain of a node; the temperature, stress and strain of the node are determined by energy conservation and stress balance through meshing.
S8: the interlayer thermal stress distribution and the residual thermal stress distribution are predicted from the result of step S7.
2. The method of claim 1 for predicting interlayer thermal stress distribution during selective laser melting based on COMSOL, wherein: step S3 further includes preprocessing the shape of the powder material to be melted stacked on the powder bed, i.e., preprocessing the apparent density of the powder, which is used to approximate the powder bed in which the powder is stacked to a rectangular parallelepiped.
3. The method of claim 2 for predicting interlayer thermal stress distribution during selective laser melting based on COMSOL, wherein: the value range of the powder apparent density is 40-60%.
4. The method of claim 3 for predicting interlayer thermal stress distribution during selective laser melting based on COMSOL, wherein: the powder had a bulk density of 50%.
5. The method of claim 1 for predicting interlayer thermal stress distribution during selective laser melting based on COMSOL, wherein: in step S4, the number of the gaussian heat sources to be moved is determined according to the slice shape, the scanning pitch, and the laser radius, so that the target slice shape can be covered by one tiling scan.
6. The method of claim 1 for predicting interlayer thermal stress distribution during selective laser melting based on COMSOL, wherein: the difference function in step S4 is determined as follows:
x_focus＝x_f1(t) (1)
wherein x represents the x direction of movement of the gaussian heat source, x _ focus represents the focus of the x to the gaussian heat source, and x _ f1(t) represents a function of the x direction of movement of the gaussian heat source;
y_focus＝y_f1(t) (2)
wherein y represents the y direction of movement of the gaussian heat source, y _ focus represents the focus of the y-direction gaussian heat source, and y _ f1(t) represents a function of the y direction of movement of the gaussian heat source;
r_focus＝sqrt((x-x_focus)^2+(y-y_focus)^2) (3)
wherein r _ focus represents a focus of the gaussian heat source, the focus is determined by a focus of the gaussian heat source in x direction and y direction, x represents an x direction of movement of the gaussian heat source, x _ focus represents a focus of the gaussian heat source in x direction, y represents a y direction of movement of the gaussian heat source, and y _ focus represents a focus of the gaussian heat source in y direction;
Flux＝((2*A_Gass*P_laser)/(pi*r_spot^2))*exp(-2*r_focus^2)/r_spot^2) (4)
wherein Flux represents the heat Flux of a Gaussian heat source, A _ Gass represents the absorptivity of a material, P _ laser represents a laser heat source, pi represents pi, r _ spot represents the laser radius, and r _ focus represents the focal point of the Gaussian heat source.
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