选择性激光烧结热物理过程分析与仿真研究
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摘要
快速原形制造技术使用逐层累加材料的方法制造零件,从制造哲理上突破了传统切削加工(材料去除)的思想桎梏。选择性激光烧结(SLS)技术是快速原形技术的一个重要分支,其工艺涉及机械、材料、粉末烧结、激光加工和传热等相关学科。本论文针对SLS中激光与粉末材料相互作用过程、激光烧结过程3D有限元仿真、基于材料特性的自适应切片技术及SLS虚拟试验系统等开展了研究工作。
分析了SLS粉末材料的构成特点,借鉴国际上流行的收集/重排堆垛模型的思想,应用Monte Carlo随机数仿真方法,构建了一种SLS粉末颗粒的新型堆垛模型,对SLS用单一尺寸和二元混合粉末材料的堆垛构形进行了仿真研究,为理论研究激光束与粉末材料相互作用提供了研究基础。在此基础上,讨论了粉末颗粒对激光束的吸收机理,建立了一种SLS光线跟踪模型,对激光束在SLS粉末颗粒中的传递、穿透行为进行了研究。综合使用所构建的SLS粉末堆垛模型和光线跟踪模型,探讨了激光波长、粉末材料组成特性等因素对吸收率的影响,同时对激光束在粉末材料中的穿透深度以及烧结区域进行了仿真研究,仿真结果与试验吻合。
针对SLS热物理过程,构建了3D温度场、应力场有限元分析模型,该模型不仅考虑了对流、辐射边界条件,以及材料热物理属性的非线性特征,而且,考虑了在粉末材料烧结成固体块材过程中热物理属性剧烈改变的问题,同时考虑了相变和激光束高斯分布特征等问题。利用有限元分析模型,对SLS过程不同的扫描路径进行了优化研究,发现在分形扫描方式中,Hilbert扫描方式达到的温度最高,烧结过程产生的平均温度梯度最小。通过仿真与树脂砂SLS的试验研究发现,与传统的“S”形扫描方式比较,Hilbert扫描方式烧结的薄板零件的变形降低了55.7%,烧结件的抗压强度提高20%左右。
开发了基于Pro/E的零件直接切片算法,该直接切片策略避免了因转换为STL文件导致的误差,可以安全、高效、精确地获取3D CAD模型的切片轮廓数据。在研究了几何自适应切片算法的基础上,提出了一种基于材料热物理特性的自适应切片方案,该切片策略综合考虑了3D模型的几何特性和SLS的工艺参数、材料热物理特性等信息,将自适应切片策略从几何层面推向物理层面进行了尝试。
综合上述研究成果开发了SLS虚拟试验系统,该虚拟试验系统能够从几何和物理层面对选择性激光烧结零件的过程进行仿真,可以对SLS激光扫描运动过程、铺粉运动过程,以及烧结过程温度场等物理信息进行3D动态显示。结合使用有限元分析工具,对SLS过程中温度场、应力场以及变形进行计算,从而为SLS的工艺优化研究开辟了一条新的途径。
Rapid prototyping & manufacturing (RP&M) as material additive manufacturing process makes a significant breakthrough in manufacturing philosophy, which is different from traditional material removal manufacturing processes e.g. metal cutting processes. Selective laser sintering (SLS) which is related to many subjects such as mechanical, material, powders sintering, laser processing, heat transfer is an important branch of RP&M. Seveal fundamental problems including interaction between powders and laser beam, 3D finite element analysis of SLS process, adaptive slicing based on material thermophysical performance are deeply investigated in this dissertation.
The characteristics of powders packing are analysed. Drawing on the ideas of collective rearrangement model and Monte Carlo stochastic simulation method, the powders packing model in SLS is proposed. The packing of the same size particles and bidisperse particles are simulated by using the model. The packing results can provide for the theoretical study on the interaction of powders and laser beam. Then, the mechanism of absorption of powders for the laser beam is disscused and the laser ray tracing (LRT) model is established. The transmission and penetrating behaviors of the laser beam within the powders are simulated by the LRT model developed. Combining the powders packing model and the LRT model, the influences of laser and powder performance on the absorption are studied. At the same time, the laser penetration depth and sintered zone are simulated and the calculated results match with that from experiments.
A 3D finite element model for calculating the evolution of temperature and thermal stresses is proposed. The model allows for the heat loss through convection and radiation, the non-linear behavior of the thermophysical performance of powders, phase change, Gaussian laser distribution, as well as the radical change of thermophysical performance during the powder-to-solid transition. The scanning patterns are optimized by using the FE model. The highest temperature and the smallest temperature gradient can be arrived by using the Hilbert scanning pattern. Compared with the traditional“S”scanning pattern, the Hilbert scanning pattern can make the maximum distortion decrease by 55.7 percent and the compressive strength increase by about 20 percent through checking the SLS parts of resin sand.
Direct slicing based on Pro/E software is proposed according to analysis of slicing strategy based on STL file. The strategy avoids the slicing errors caused by conversion from 3D CAD to STL file. The slicing contour of 3D CAD model can be arrived through the safe, efficient, accurate direct slicing method. Adaptive slicing strategy based on thermophysical performance is proposed. The strategy considers a few of aspects including geometric features of 3D CAD model, SLS processing parameters, as well as thermophysical characteristics etc. An effort is made for pushing geometric adaptive slicing to physical adaptive slicing.
A SLS virtual experimental system is developed by integration with the research fruits obtained herein. The system can simulate the SLS machining process from geometric and physical level, including 3D dynamic display of the laser scanning system, spreading powder system, temperature evolution. Using FE tools, temperature, stresses and distortion in SLS process can be caculated. The system will be benefit for the optimization of SLS process.
分析了SLS粉末材料的构成特点,借鉴国际上流行的收集/重排堆垛模型的思想,应用Monte Carlo随机数仿真方法,构建了一种SLS粉末颗粒的新型堆垛模型,对SLS用单一尺寸和二元混合粉末材料的堆垛构形进行了仿真研究,为理论研究激光束与粉末材料相互作用提供了研究基础。在此基础上,讨论了粉末颗粒对激光束的吸收机理,建立了一种SLS光线跟踪模型,对激光束在SLS粉末颗粒中的传递、穿透行为进行了研究。综合使用所构建的SLS粉末堆垛模型和光线跟踪模型,探讨了激光波长、粉末材料组成特性等因素对吸收率的影响,同时对激光束在粉末材料中的穿透深度以及烧结区域进行了仿真研究,仿真结果与试验吻合。
针对SLS热物理过程,构建了3D温度场、应力场有限元分析模型,该模型不仅考虑了对流、辐射边界条件,以及材料热物理属性的非线性特征,而且,考虑了在粉末材料烧结成固体块材过程中热物理属性剧烈改变的问题,同时考虑了相变和激光束高斯分布特征等问题。利用有限元分析模型,对SLS过程不同的扫描路径进行了优化研究,发现在分形扫描方式中,Hilbert扫描方式达到的温度最高,烧结过程产生的平均温度梯度最小。通过仿真与树脂砂SLS的试验研究发现,与传统的“S”形扫描方式比较,Hilbert扫描方式烧结的薄板零件的变形降低了55.7%,烧结件的抗压强度提高20%左右。
开发了基于Pro/E的零件直接切片算法,该直接切片策略避免了因转换为STL文件导致的误差,可以安全、高效、精确地获取3D CAD模型的切片轮廓数据。在研究了几何自适应切片算法的基础上,提出了一种基于材料热物理特性的自适应切片方案,该切片策略综合考虑了3D模型的几何特性和SLS的工艺参数、材料热物理特性等信息,将自适应切片策略从几何层面推向物理层面进行了尝试。
综合上述研究成果开发了SLS虚拟试验系统,该虚拟试验系统能够从几何和物理层面对选择性激光烧结零件的过程进行仿真,可以对SLS激光扫描运动过程、铺粉运动过程,以及烧结过程温度场等物理信息进行3D动态显示。结合使用有限元分析工具,对SLS过程中温度场、应力场以及变形进行计算,从而为SLS的工艺优化研究开辟了一条新的途径。
Rapid prototyping & manufacturing (RP&M) as material additive manufacturing process makes a significant breakthrough in manufacturing philosophy, which is different from traditional material removal manufacturing processes e.g. metal cutting processes. Selective laser sintering (SLS) which is related to many subjects such as mechanical, material, powders sintering, laser processing, heat transfer is an important branch of RP&M. Seveal fundamental problems including interaction between powders and laser beam, 3D finite element analysis of SLS process, adaptive slicing based on material thermophysical performance are deeply investigated in this dissertation.
The characteristics of powders packing are analysed. Drawing on the ideas of collective rearrangement model and Monte Carlo stochastic simulation method, the powders packing model in SLS is proposed. The packing of the same size particles and bidisperse particles are simulated by using the model. The packing results can provide for the theoretical study on the interaction of powders and laser beam. Then, the mechanism of absorption of powders for the laser beam is disscused and the laser ray tracing (LRT) model is established. The transmission and penetrating behaviors of the laser beam within the powders are simulated by the LRT model developed. Combining the powders packing model and the LRT model, the influences of laser and powder performance on the absorption are studied. At the same time, the laser penetration depth and sintered zone are simulated and the calculated results match with that from experiments.
A 3D finite element model for calculating the evolution of temperature and thermal stresses is proposed. The model allows for the heat loss through convection and radiation, the non-linear behavior of the thermophysical performance of powders, phase change, Gaussian laser distribution, as well as the radical change of thermophysical performance during the powder-to-solid transition. The scanning patterns are optimized by using the FE model. The highest temperature and the smallest temperature gradient can be arrived by using the Hilbert scanning pattern. Compared with the traditional“S”scanning pattern, the Hilbert scanning pattern can make the maximum distortion decrease by 55.7 percent and the compressive strength increase by about 20 percent through checking the SLS parts of resin sand.
Direct slicing based on Pro/E software is proposed according to analysis of slicing strategy based on STL file. The strategy avoids the slicing errors caused by conversion from 3D CAD to STL file. The slicing contour of 3D CAD model can be arrived through the safe, efficient, accurate direct slicing method. Adaptive slicing strategy based on thermophysical performance is proposed. The strategy considers a few of aspects including geometric features of 3D CAD model, SLS processing parameters, as well as thermophysical characteristics etc. An effort is made for pushing geometric adaptive slicing to physical adaptive slicing.
A SLS virtual experimental system is developed by integration with the research fruits obtained herein. The system can simulate the SLS machining process from geometric and physical level, including 3D dynamic display of the laser scanning system, spreading powder system, temperature evolution. Using FE tools, temperature, stresses and distortion in SLS process can be caculated. The system will be benefit for the optimization of SLS process.
引文
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