CN113139314B - A Numerical Simulation Method of Heat Source for Laser Additive Manufacturing Process - Google Patents
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Abstract
Description
技术领域technical field
本发明属于工艺热源数值模拟技术领域，尤其涉及一种用于激光增材制造工艺的热源数值模拟方法。The invention belongs to the technical field of process heat source numerical simulation, and in particular relates to a heat source numerical simulation method for a laser additive manufacturing process.
背景技术Background technique
增材制造是通过控制材料逐层堆积实现三维零件的制造的工艺，与传统的制造方式相比，增材制造无需昂贵的模具，可以大大缩短研发周期和制造成本，并能制造形状更加复杂的零件。针对该工艺设计与优化目前国内还主要依赖经验和多次试验验证，而国外则偏向于基础研究和工艺数值模拟。随着数值模拟技术和增材制造工艺的发展与提升，为了更好地评估制造工艺的应力应变分布，对于制造过程温度场模拟的精确度要求越来越高。因此，合理的热源模型及计算流程是实现增材制造工艺过程模拟的基础条件和重要保证。Additive manufacturing is a process of manufacturing three-dimensional parts by controlling the layer-by-layer accumulation of materials. Compared with traditional manufacturing methods, additive manufacturing does not require expensive molds, which can greatly shorten the development cycle and manufacturing cost, and can manufacture more complex shapes. Components. For the process design and optimization, China still mainly relies on experience and multiple test verifications, while foreign countries tend to rely on basic research and process numerical simulation. With the development and improvement of numerical simulation technology and additive manufacturing process, in order to better evaluate the stress and strain distribution of the manufacturing process, the accuracy of the temperature field simulation of the manufacturing process is getting higher and higher. Therefore, a reasonable heat source model and calculation process are the basic conditions and important guarantees for the realization of additive manufacturing process simulation.
增材制造热循环历程重复而又复杂，数值模拟可作为有效技术手段进行增材过程热-力行为的分析研究，而热源模型的准确性是增材制造数值模拟成功的关键。目前增材制造工艺数值模拟过程，对热源的模拟都是用通用热源模型或能量函数来进行简化和替代，缺乏系统性地表征和构建，计算精度和效率较低，无法满足增材制造工艺数值计算需要。综上，增材制造工艺热源模拟是目前工程和科学界研究的难点和重点。The thermal cycle history of additive manufacturing is repetitive and complex. Numerical simulation can be used as an effective technical means to analyze and study the thermal-mechanical behavior of additive manufacturing process. The accuracy of the heat source model is the key to the success of additive manufacturing numerical simulation. At present, in the numerical simulation process of additive manufacturing process, the simulation of heat source is simplified and replaced by general heat source model or energy function, which lacks systematic characterization and construction, and the calculation accuracy and efficiency are low, which cannot meet the numerical value of additive manufacturing process. calculation needs. To sum up, heat source simulation of additive manufacturing process is the difficulty and focus of current engineering and scientific research.
发明内容SUMMARY OF THE INVENTION
针对现有技术中的上述不足，本发明提供的一种用于激光增材制造的工艺热源数值确模拟方法，不仅能提高计算效率并且还具有高效稳定性的优点。In view of the above deficiencies in the prior art, the present invention provides a method for numerically accurate simulation of a process heat source for laser additive manufacturing, which not only improves computing efficiency but also has the advantages of high efficiency and stability.
为了达到以上目的，本发明采用的技术方案为：In order to achieve the above purpose, the technical scheme adopted in the present invention is:
本方案提供一种用于激光增材制造工艺的热源数值模拟方法，包括以下步骤：This solution provides a heat source numerical simulation method for a laser additive manufacturing process, including the following steps:
S1、基于激光增材制造零部件温度场分布形状，确定工艺熔池区域的关键参数；S1. Determine the key parameters of the process melt pool area based on the shape of the temperature field distribution of the laser additive manufacturing parts;
S2、基于激光增材制造工艺特征和热源影响区域的几何分布结构，构建初始热源数值模型；S2. Build an initial heat source numerical model based on the laser additive manufacturing process characteristics and the geometric distribution structure of the heat source affected area;
S3、根据所述初始热源数值模型，计算得到关于激光增材制造工艺热源计算温度分布以及关于热源的几何形貌尺寸；S3. According to the initial heat source numerical model, the calculated temperature distribution of the heat source in the laser additive manufacturing process and the geometric shape size of the heat source are obtained;
S4、根据步骤S1得到的工艺熔池区域的关键参数与所述步骤S3的计算结果，对初始热源数值模型中的关键参数进行校核，得到优化后的热源数值模型；S4, according to the key parameters of the process molten pool area obtained in step S1 and the calculation result of the step S3, check the key parameters in the initial heat source numerical model to obtain an optimized heat source numerical model;
S5、将步骤S3的计算步骤代入所述优化后的热源数值模型进行热源几何形貌尺寸计算，完成热源数值的模拟。S5. Substitute the calculation step of step S3 into the optimized heat source numerical model to calculate the geometry and size of the heat source, and complete the numerical simulation of the heat source.
本发明的有益效果是：本发明针对激光增材制造工艺特点和数值模拟计算需要创新性地发明针对该种工艺的热源数值计算模型，并定义工艺模型热源计算流程，使其能构建精确的热源计算模型并能够应用于激光增材制造工艺中，实现对各种不同厚度和零件尺寸的激光增材工艺成形数值计算，该热源数值模型与计算流程，不仅能提高计算效率并且还具有流程化的优点，并能够最大程度地提高激光增材制造中工艺温度场数值模拟热源模型建立的准确性。The beneficial effects of the invention are as follows: the invention needs to innovatively invent a heat source numerical calculation model for this kind of process according to the characteristics of the laser additive manufacturing process and numerical simulation calculation, and define the process model heat source calculation process, so that it can construct an accurate heat source The calculation model can be applied to the laser additive manufacturing process to realize the numerical calculation of laser additive process forming of various thicknesses and part sizes. The heat source numerical model and calculation process can not only improve the calculation efficiency, but also have a streamlined process. Advantages, and can maximize the accuracy of the establishment of the heat source model for the numerical simulation of the process temperature field in the laser additive manufacturing.
进一步地，所述步骤S2中热源数值模型的表达式如下：Further, the expression of the heat source numerical model in the step S2 is as follows:
其中，Q表示热源数据模型，Q0表示初始最大输入能量密度，ri和re表示底端和上端面半径，r和R分别表示激光增材粉末和热源半径，zi和ze分别表示底端和上端坐标值，x,y,z表示移动沿三个方向的坐标值，t表示时间，h表示熔池区域的高度，yt+Δt、yt、zt+Δt和zt分别为t+Δt和t时刻y和z方向坐标值，xt+Δt和xt分别表示t+Δt和t时刻x方向坐标值，C表示上端热源能量分布系数，r表示上端热源半径。Among them, Q represents the heat source data model, Q 0 represents the initial maximum input energy density, ri and r e represent the bottom and upper end face radii, r and R represent the laser additive powder and heat source radii , respectively, zi and ze represent The coordinate values of the bottom end and the upper end, x, y, z represent the coordinate values of the movement along the three directions, t represents the time, h represents the height of the molten pool area, y t+Δt , y t , z t+Δt and z t respectively are the y- and z-direction coordinate values at t+Δt and t, x t+Δt and x t represent the x-direction coordinate values at t+Δt and t, respectively, C represents the energy distribution coefficient of the upper heat source, and r represents the radius of the upper heat source.
上述进一步方案的有益效果是：定义了与试件板厚和打印位置相关的激光增材制造工艺数值模拟热源模型。The beneficial effect of the above-mentioned further scheme is that the numerical simulation heat source model of the laser additive manufacturing process related to the plate thickness of the test piece and the printing position is defined.
再进一步地，所述步骤S3中几何形貌尺寸的表达式如下：Still further, the expression of the geometry size in the step S3 is as follows:
其中，hsolver和wsolver分别表示计算所得熔池深度和宽度，λ表示材料热导率，A表示试件截面面积，t表示时间，Q表示热源能量，Th，Tw，T0分别表示在熔深方向和熔宽方向某一点的温度，即熔深和熔宽初始温度。Among them, h solver and w solver represent the depth and width of the molten pool obtained by calculation, λ represents the thermal conductivity of the material, A represents the cross-sectional area of the specimen, t represents the time, Q represents the energy of the heat source, T h , Tw , T 0 represent respectively The temperature at a certain point in the direction of penetration and width, that is, the initial temperature of penetration and width.
上述进一步方案的有益效果是：利用所定义的激光增材制造工艺数值模拟热源模型计算了温度场并且确定了所计算的熔池深度和宽度值。The beneficial effects of the above-mentioned further solution are: using the defined laser additive manufacturing process numerical simulation heat source model to calculate the temperature field and to determine the calculated value of the depth and width of the molten pool.
再进一步地，所述步骤S4中进行校核的方程为：Further, the equation for checking in the step S4 is:
hsolver＝h×kh h solver = h×k h
wsolver＝w×kw w solver = w × k w
其中，hsolver和wsolver分别表示计算所得熔池深度和宽度，kh和kw分别表示熔深和熔宽敏感系数，h表示实测熔池深度，w表示实测熔池宽度。Among them, h solver and w solver represent the calculated melt pool depth and width, respectively, k h and k w represent the penetration depth and melt width sensitivity coefficients, respectively, h represents the measured melt pool depth, and w represents the measured melt pool width.
上述进一步方案的有益效果是：利用所定义的激光增材制造工艺数值模拟热源模型计算的熔池深度和宽度值与实测结果进行对比，获得熔池深度和宽带方向的修改系数。The beneficial effect of the above-mentioned further scheme is that the molten pool depth and width calculated by the defined laser additive manufacturing process numerical simulation heat source model are compared with the measured results, and the modification coefficients of the molten pool depth and the broadband direction are obtained.
再进一步地，所述步骤S4中优化后的热源数值模型的表达式如下：Still further, the expression of the heat source numerical model optimized in the step S4 is as follows:
其中，Q'表示修改后的热源数值模型，Q0表示初始最大输入能量密度，ri和re表示底端和上端面半径，r和R分别表示激光增材粉末和热源半径，zi和ze分别表示底端和上端坐标值，x,y,z表示移动沿三个方向的坐标值，t表示时间，h表示熔池区域的高度，yt+Δt、yt、zt+Δt和zt分别为t+Δt和t时刻y和z方向坐标值，xt+Δt和xt分别表示t+Δt和t时刻x方向坐标值，C表示上端热源能量分布系数，r表示上端热源半径，kh和kw分别表示熔深和熔宽敏感系数。where Q' represents the modified numerical model of the heat source, Q 0 represents the initial maximum input energy density, ri and r e represent the bottom and upper end face radii, r and R represent the laser additive powder and heat source radii , respectively, zi and z e represents the coordinate values of the bottom and upper ends respectively, x, y, z represent the coordinate values of the movement along three directions, t represents the time, h represents the height of the molten pool area, y t+Δt , y t , z t+Δt and z t are the coordinate values in the y and z directions at t+Δt and t, respectively, x t+Δt and x t are the coordinate values in the x direction at t+Δt and t, respectively, C is the energy distribution coefficient of the upper heat source, and r is the upper heat source. Radius, k h and k w represent penetration and penetration sensitivity coefficients, respectively.
上述进一步方案的有益效果是：根据与实测值获得的修正系数进一步对激光增材制造工艺数值模拟热源模型进行了修改，获得了用于激光增材制造工艺的热源优化数值模型。The beneficial effect of the above-mentioned further scheme is that the numerical simulation heat source model of the laser additive manufacturing process is further modified according to the correction coefficient obtained from the measured value, and a heat source optimization numerical model for the laser additive manufacturing process is obtained.
附图说明Description of drawings
图1为本发明的方法流程图。FIG. 1 is a flow chart of the method of the present invention.
图2为本实施例中热源模型示意图。FIG. 2 is a schematic diagram of a heat source model in this embodiment.
图3为本实施例中底部热源模型示意图。FIG. 3 is a schematic diagram of the bottom heat source model in this embodiment.
具体实施方式Detailed ways
下面对本发明的具体实施方式进行描述，以便于本技术领域的技术人员理解本发明，但应该清楚，本发明不限于具体实施方式的范围，对本技术领域的普通技术人员来讲，只要各种变化在所附的权利要求限定和确定的本发明的精神和范围内，这些变化是显而易见的，一切利用本发明构思的发明创造均在保护之列。The specific embodiments of the present invention are described below to facilitate those skilled in the art to understand the present invention, but it should be clear that the present invention is not limited to the scope of the specific embodiments. For those of ordinary skill in the art, as long as various changes Such changes are obvious within the spirit and scope of the present invention as defined and determined by the appended claims, and all inventions and creations utilizing the inventive concept are within the scope of protection.
实施例Example
基于现有技术的不足，本发明针对激光增材制造工艺特点和数值模拟计算定义工艺模型热源及其计算流程，使其能够应用于激光增材制造工艺中并适应各种不同厚度和零件尺寸的工艺成形数值计算，本方法不仅能提高计算效率并且还具有高效稳定性的优点，如图1所示，包括以下步骤：Based on the deficiencies of the prior art, the present invention defines a process model heat source and its calculation process according to the characteristics of the laser additive manufacturing process and numerical simulation calculation, so that it can be applied to the laser additive manufacturing process and adapt to various thicknesses and part sizes. For numerical calculation of process forming, this method can not only improve the calculation efficiency but also have the advantages of high efficiency and stability, as shown in Figure 1, including the following steps:
S1、基于激光增材制造零部件温度场分布形状，确定工艺熔池区域的关键参数；S1. Determine the key parameters of the process melt pool area based on the shape of the temperature field distribution of the laser additive manufacturing parts;
本实施例中，如图2所示，关键参数包括熔池深度(h)，熔池下端宽度(w1)和上端宽度(w2)。In this embodiment, as shown in FIG. 2 , the key parameters include the depth of the molten pool (h), the width of the lower end of the molten pool (w 1 ) and the width of the upper end (w 2 ).
S2、基于激光增材制造工艺特征和熔池区域的几何分布结构，构建初始热源数值模型，具体表达式如下所示：S2. Based on the characteristics of the laser additive manufacturing process and the geometric distribution structure of the molten pool area, a numerical model of the initial heat source is constructed. The specific expression is as follows:
Q＝Qdown+Qtop (1)Q=Q down +Q top (1)
其中，Q为整体热源；Qdown为底部热源；Qtop为上端热源。Among them, Q is the overall heat source; Q down is the bottom heat source; Q top is the upper heat source.
根据激光增材制造工艺过程，实际的底端热源Qdown呈现三维热源特征，如图3所示，同时该局部热源又与打印速度和空间位置相关，因此其函数表达式为：According to the laser additive manufacturing process, the actual bottom heat source Q down presents the characteristics of a three-dimensional heat source, as shown in Figure 3. At the same time, the local heat source is related to the printing speed and spatial position, so its function expression is:
其中，Q0为初始最大输入能量密度；x,y,z为热源移动沿三个方向的坐标值；r0为底端热源名义半径；ri，re分别为底端和上端面半径；zi和ze分别为热源底端和上端坐标值；f(x,y,z,v)为激光增材制造工艺热源系数；r和R分别为激光增材粉末和热源半径；h表示熔池区域的高度；t为时间；xt+Δt和xt分别为t+Δt和t时刻x方向坐标值；yt+Δt、yt、zt+Δt、zt分别为t+Δt和t时刻y和z方向坐标值；C为上端热源能量分布系数；r为上端热源半径。Among them, Q 0 is the initial maximum input energy density; x, y, z are the coordinate values of the heat source moving along three directions; r 0 is the nominal radius of the bottom heat source; ri and r e are the radii of the bottom and upper end surfaces, respectively; zi and z e are the coordinates of the bottom and upper ends of the heat source, respectively; f(x, y, z, v) is the heat source coefficient of the laser additive manufacturing process; r and R are the radius of the laser additive powder and the heat source, respectively; h is the melting point height of the pool area; t is time; x t+Δt and x t are the x-direction coordinate values at t+Δt and t, respectively; y t+Δt , y t , z t+Δt , and z t are t+Δt and Coordinate values in y and z directions at time t; C is the energy distribution coefficient of the upper heat source; r is the radius of the upper heat source.
综上，初始热源数值模型为：In summary, the numerical model of the initial heat source is:
S3、根据所述初始热源数值模型，计算得到关于激光增材制造工艺热源计算温度分布以及关于热源的几何形貌尺寸；S3. According to the initial heat source numerical model, the calculated temperature distribution of the heat source in the laser additive manufacturing process and the geometric shape size of the heat source are obtained;
本实施例中，把公式(6)离散带入有限元软件中或编程进行计算，获得关于激光增材制造工艺热源计算温度分布，完成增材制造工艺热源计算，获得关于热源几何形貌尺寸，比如熔深、熔宽等，其中：In this embodiment, formula (6) is discretely brought into the finite element software or programmed to calculate, to obtain the calculated temperature distribution of the heat source in the laser additive manufacturing process, to complete the calculation of the heat source of the additive manufacturing process, and to obtain the geometric shape and size of the heat source, Such as penetration depth, penetration width, etc., of which:
其中，hsolver和wsolver分别为计算所得熔池深度和宽度；λ为材料热导率；A为试件截面面积；t为时间；Q为热源能量；Th，Tw，T0分别为在熔深方向和熔宽方向某一点的温度，及熔深和熔宽初始温度。Among them, h solver and w solver are the depth and width of the molten pool obtained by calculation; λ is the thermal conductivity of the material; A is the cross-sectional area of the specimen; t is the time; Q is the heat source energy; T h , T w , T 0 are respectively The temperature at a certain point in the direction of penetration and width, and the initial temperature of penetration and width.
S4、根据步骤S1得到的工艺熔池区域的关键参数与所述步骤S3的计算结果，对初始热源数值模型中的关键参数进行校核，得到优化后的热源数值模型；S4, according to the key parameters of the process molten pool area obtained in step S1 and the calculation result of the step S3, check the key parameters in the initial heat source numerical model to obtain an optimized heat source numerical model;
本实施例中，熔深尺寸校核：根据公式(6)的计算结果获得材料焊接过程熔池深度，然后与步骤S1中试验获得的标准熔深对比，若小于，则说明模拟热源尺寸在深度方向即Z方向能量或尺寸不够，需要再增大；若大于，则说明模拟热源尺寸在深度方向即Z方向能量或尺寸过高，需要降低。In the present embodiment, the penetration size check: according to the calculation result of the formula (6), the depth of the molten pool in the material welding process is obtained, and then compared with the standard penetration depth obtained by the test in step S1. If it is smaller than the size of the simulated heat source, the depth If the energy or size of the direction, that is, the Z direction, is not enough, it needs to be increased; if it is larger, it means that the size of the simulated heat source is too high in the depth direction, that is, the energy or size of the Z direction, and needs to be reduced.
本实施例中，熔宽尺寸校核：根据公式(6)的计算结果获得材料焊接过程熔池宽度，然后与S1中试验获得的标准熔宽对比(步骤S1中的关键参数是指熔池尺寸，包括熔池区高度(h)，下端宽度(w1)和上端宽度(w2))，若小于，则说明模拟热源尺寸在宽度方向即X方向能量或尺寸不够，需要再增大；若大于S1结果，则说明模拟热源尺寸在宽度方向即X方向能量或尺寸过高，需要降低。In this embodiment, the size of the melt width is checked: the width of the melt pool during the material welding process is obtained according to the calculation result of formula (6), and then compared with the standard melt width obtained by the test in S1 (the key parameter in step S1 refers to the size of the melt pool) , including the height of the molten pool area (h), the width of the lower end (w 1 ) and the width of the upper end (w 2 )), if it is smaller than the size of the simulated heat source in the width direction, that is, the X-direction energy or size is not enough, and it needs to be increased; if If it is larger than the result of S1, it means that the size of the simulated heat source in the width direction, that is, the X-direction energy or size is too high and needs to be reduced.
本实施例中，根据关于熔池深和熔池宽尺寸的确定，可以综合获得熔深与熔宽综合对比组合，设立方程如下所示：In this embodiment, according to the determination of the size of the molten pool depth and the molten pool width, a comprehensive comparison combination of the molten pool depth and the molten pool width can be comprehensively obtained, and the established equation is as follows:
hsolver＝h×kh h solver = h×k h
wsolver＝w×kw w solver = w × k w
其中，kh和kw分别为熔深和熔宽敏感系数。因此，经过优化计算后，方程(6)可表达为：Among them, k h and k w are penetration and penetration sensitivity coefficients, respectively. Therefore, after the optimization calculation, equation (6) can be expressed as:
本实施例中，利用步骤S1中得到的实际热源几何形貌尺寸与计算结果进行比对分析，进行激光增材制造热源模型中关键参数校核，完善和精确热源数值计算模型。In this embodiment, the actual heat source geometry size obtained in step S1 and the calculation result are used to compare and analyze, to check the key parameters in the laser additive manufacturing heat source model, and to improve and accurately calculate the heat source numerical calculation model.
S5、将步骤S3的计算步骤代入所述优化后的热源数值模型进行热源几何形貌尺寸计算，完成热源数值的模拟。S5. Substitute the calculation step of step S3 into the optimized heat source numerical model to calculate the geometry and size of the heat source, and complete the numerical simulation of the heat source.
本发明针对激光增材制造工艺特点和数值模拟计算创新性地发明针对该种工艺的热源数值计算模型，并定义工艺模型热源计算流程，使其能构建精确的热源计算模型并能够应用于激光增材制造工艺中，实现对各种不同厚度和零件尺寸的激光增材工艺成形数值计算，该热源数值模型与计算流程，不仅能提高计算效率并且还具有流程化的优点，并能够最大程度地提高激光增材制造中工艺温度场数值模拟热源模型建立的准确性。According to the characteristics of the laser additive manufacturing process and numerical simulation calculation, the present invention innovatively invents a heat source numerical calculation model for this process, and defines the process model heat source calculation process, so that an accurate heat source calculation model can be constructed and applied to the laser additive manufacturing process. In the material manufacturing process, the numerical calculation of laser additive process forming of various thicknesses and part sizes is realized. The numerical model and calculation process of the heat source can not only improve the calculation efficiency, but also have the advantages of processization, and can maximize the improvement of the heat source. Accuracy of heat source model establishment for numerical simulation of process temperature field in laser additive manufacturing.
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