A Simulation Method for Electron Beam Additive Manufacturing Process

Abstract

This invention discloses a simulation method for electron beam additive manufacturing. Addressing the characteristics of electron beam additive manufacturing and the needs of numerical simulation, it innovatively proposes an additive manufacturing simulation model for this process, and outlines activation procedures for additive manufacturing units and heat source location procedures. This enables the construction of a reasonable additive manufacturing simulation model that can be applied to electron beam additive manufacturing, achieving full-process numerical simulation of a cubic additive manufacturing process. This invention streamlines and simplifies the additive manufacturing process calculation process, enabling full-process simulation of electron beam additive manufacturing. It can help improve additive manufacturing parameters, provide an effective simulation analysis tool for electron beam additive manufacturing, and offer a new path for process optimization.

Description

Technical Field

[0001] This invention belongs to the field of electron beam additive manufacturing technology, specifically relating to the design of an electron beam additive manufacturing process simulation method. Background Technology

[0002] Electron beam additive manufacturing is an additive manufacturing technology that uses a high-energy electron beam as a heat source to melt and solidify materials (usually metal powders), thereby achieving layer-by-layer material deposition. Compared with traditional manufacturing methods, electron beam additive manufacturing can rapidly produce parts, significantly shortening the R&D cycle and reducing manufacturing costs. Currently, the design and optimization of this process in China mainly relies on experience and repeated experimental verification, while abroad, the focus is more on basic research and process numerical simulation. With the widespread application of additive manufacturing in industry, rapidly evaluating the stress-strain distribution of the manufacturing process and adjusting process parameters through numerical simulation has become an indispensable part of additive manufacturing. Process simulation of electron beam additive manufacturing is a crucial guarantee for the large-scale industrial application of this technology.

[0003] To simulate electron beam additive manufacturing, modeling the entire process is necessary. While extensive research on heat sources provides a solid theoretical foundation, a suitable simulation method has yet to be developed for modeling the physical process of material addition, hindering convenient additive manufacturing simulation. Summary of the Invention

[0004] The purpose of this invention is to solve the problem that existing electron beam additive manufacturing process simulation methods are difficult to achieve convenient additive manufacturing simulation. This invention proposes an electron beam additive manufacturing process simulation method that can quickly complete the setup of additive manufacturing and optimize additive manufacturing process parameters.

[0005] The technical solution of this invention is: a simulation method for electron beam additive manufacturing process, comprising the following steps:

[0006] S1. Based on the actual electron beam additive manufacturing process, determine the heat source moving speed and construct a cubic model of electron beam additive manufacturing.

[0007] S2. Construct an additive unit activation model based on the heat source movement speed and the electron beam additive manufacturing cubic model.

[0008] S3. Construct a heat source location model based on the heat source movement speed and the electron beam additive manufacturing cubic model.

[0009] S4. Match the additive unit activation model and the heat source location model.

[0010] S5. Using finite element software, perform heat conduction analysis on the matched additive unit activation model and heat source location model to obtain the temperature field distribution of the additive manufacturing process.

[0011] S6. Analyze the temperature field distribution, modify the parameters of the heat source location model based on the analysis results, improve the heat source location model, realize the simulation of electron beam additive manufacturing process, and improve the electron beam additive manufacturing process based on the simulation results.

[0012] Furthermore, the construction of the electron beam additive manufacturing cubic model in step S1 includes determining the length L, width W, height H, and cell size L of the cubic model. element And set the length L along the x-axis, the width W along the z-axis, and the height H along the y-axis.

[0013] Furthermore, step S2 includes the following sub-steps:

[0014] S21. Establish the additive unit activation sequence based on the heat source movement speed and the electron beam additive manufacturing cubic model:

[0015]

[0016] Where n l n w n h t represents the number of elements in the length, width, and height directions of the cubic model, respectively. d V represents the time required to complete one cell of additive manufacturing. hs This indicates the speed at which the heat source moves.

[0017] S22. Initialize settings: time t = 0, additive manufacturing layer count Row = 0, y-axis parameter y = 0.5L element .

[0018] S23. Determine whether Row < n is satisfied. h If yes, proceed to step S24; otherwise, proceed to step S3.

[0019] S24. Set the number of cells for additive manufacturing (Column) to 0, and the x-axis direction parameter to x = 0.5L. element .

[0020] S25. Determine if Column < n is satisfied. l If yes, proceed to step S26; otherwise, increment the additive manufacturing layer number Row by 1 and increase the y-axis parameter y by one cell size L. element Return to step S23.

[0021] S26. Set the number of columns for additive manufacturing (Line = 0) and the z-axis parameter (z = 0.5L). element .

[0022] S27. Determine whether Line < n is satisfied. w If yes, proceed to step S28; otherwise, increment the number of additive manufacturing cells (Column) by 1 and increase the x-axis direction parameter (x) by one cell size (L). element Return to step S25.

[0023] S28. At time t, activate the cell at coordinates (x, y, z), increment the additive manufacturing column number Line by 1, and increase the z-axis direction parameter z by one cell size L. element Time t increases by t d Return to step S27.

[0024] Furthermore, step S3 includes the following sub-steps:

[0025] S31. Calculate the time t required to complete one train in additive manufacturing based on the heat source moving speed and the cubic model of electron beam additive manufacturing. line The time t required to complete one layer of additive manufacturing row :

[0026]

[0027] t row =t line n l

[0028] S32. Obtain the current time t and the initial position of the heat source (x0, y0, z0).

[0029] S33. Calculate the total distance d that the heat source has moved based on the current time t:

[0030] d=V hs ×t

[0031] S34. Calculate the total number of columns i completed in the additive manufacturing process, the number of columns j in the current layer during the additive manufacturing process, and the number of layers k during the additive manufacturing process based on the current time t:

[0032]

[0033] j = mod(i, n) l )

[0034]

[0035] Where floor(·) represents the floor function and mod(·) represents the modulo function.

[0036] S35. Calculate the current heat source location (x) hs ,y hs ,z hs ):

[0037] x hs =j×L element +x0

[0038] y hs =k×L element +y0

[0039] z hs =-i×n w ×L element +d+z0

[0040] The beneficial effects of this invention are:

[0041] (1) In view of the characteristics of electron beam additive manufacturing process and the need for numerical simulation calculation, this invention innovatively proposes an additive manufacturing simulation calculation model for this process, and proposes an additive process unit activation process and a heat source location process, so that it can build a reasonable additive manufacturing simulation calculation model and be applied to electron beam additive manufacturing process, and realize the full process numerical simulation of a cubic additive manufacturing process.

[0042] (2) The additive manufacturing simulation calculation process constructed by this invention can quickly complete the model establishment, which not only improves the simulation calculation efficiency but also has the advantage of process-oriented approach. It can also provide an effective simulation analysis method for electron beam additive manufacturing process and provide a new path for process optimization. Attached Figure Description

[0043] Figure 1 The diagram shown is a flowchart of an electron beam additive manufacturing process simulation method provided by an embodiment of the present invention.

[0044] Figure 2 The diagram shown is a schematic diagram of an electron beam additive manufacturing cubic model provided in an embodiment of the present invention. Detailed Implementation

[0045] Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be understood that the embodiments shown and described in the drawings are merely exemplary and are intended to illustrate the principles and spirit of the invention, and are not intended to limit the scope of the invention.

[0046] This invention provides a simulation method for electron beam additive manufacturing processes, such as... Figure 1 As shown, it includes the following steps S1 to S6:

[0047] S1. Based on the actual electron beam additive manufacturing process, determine the heat source moving speed and construct a cubic model of electron beam additive manufacturing.

[0048] In this embodiment of the invention, the constructed electron beam additive manufacturing cubic model is as follows: Figure 2As shown, it is necessary to determine the length L, width W, height H, and cell size L of the cube model. element And set the length L along the x-axis, the width W along the z-axis, and the height H along the y-axis.

[0049] S2. Construct an additive unit activation model based on the heat source movement speed and the electron beam additive manufacturing cubic model.

[0050] Step S2 includes the following sub-steps S21 to S28:

[0051] S21. Establish the additive unit activation sequence based on the heat source movement speed and the electron beam additive manufacturing cubic model:

[0052]

[0053] Where n l n w n h t represents the number of elements in the length, width, and height directions of the cubic model, respectively. d V represents the time required to complete one cell of additive manufacturing. hs This indicates the speed at which the heat source moves.

[0054] S22. Initialize settings: time t = 0, additive manufacturing layer count Row = 0, y-axis parameter y = 0.5L element .

[0055] S23. Determine whether Row < n is satisfied. h If yes, proceed to step S24; otherwise, proceed to step S3.

[0056] S24. Set the number of cells for additive manufacturing (Column) to 0, and the x-axis direction parameter to x = 0.5L. element .

[0057] S25. Determine if Column < n is satisfied. l If yes, proceed to step S26; otherwise, increment the additive manufacturing layer number Row by 1 and increase the y-axis parameter y by one cell size L. element Return to step S23.

[0058] S26. Set the number of columns for additive manufacturing (Line = 0) and the z-axis parameter (z = 0.5L). element .

[0059] S27. Determine whether Line < n is satisfied. w If yes, proceed to step S28; otherwise, increment the number of additive manufacturing cells (Column) by 1 and increase the x-axis direction parameter (x) by one cell size (L). element Return to step S25.

[0060] S28. At time t, activate the cell at coordinates (x, y, z), increment the additive manufacturing column number Line by 1, and increase the z-axis direction parameter z by one cell size L. element Time t increases by t d Return to step S27.

[0061] In this embodiment of the invention, it is assumed that the heat source starts from the origin and travels along the width W (z-axis) to complete a path with length W and width L. element A column of additive manufacturing, then shifted one cell size L in the positive x-axis direction. element Then, another layer of additive manufacturing is completed along the positive z-axis. This process is repeated until one layer of additive manufacturing is complete. When moving to the next layer, the heat source will move one cell size L along the positive y-axis. element The process is repeated from the previous layer, and repeated multiple times until the additive manufacturing of the entire cubic model is completed.

[0062] S3. Construct a heat source location model based on the heat source movement speed and the electron beam additive manufacturing cubic model.

[0063] Step S3 includes the following sub-steps S31 to S35:

[0064] S31. Calculate the time t required to complete one train in additive manufacturing based on the heat source moving speed and the cubic model of electron beam additive manufacturing. line The time t required to complete one layer of additive manufacturing row :

[0065]

[0066] t row =t line n l

[0067] S32. Obtain the current time t and the initial position of the heat source (x0, y0, z0).

[0068] S33. Calculate the total distance d that the heat source has moved based on the current time t:

[0069] d=V hs ×t

[0070] S34. Calculate the total number of columns i completed in the additive manufacturing process, the number of columns j in the current layer during the additive manufacturing process, and the number of layers k during the additive manufacturing process based on the current time t:

[0071]

[0072] j = mod(i, n) l )

[0073]

[0074] Where floor(·) represents the floor function and mod(·) represents the modulo function.

[0075] S35. Calculate the current heat source location (x) hs ,y hs ,z hs ):

[0076] x hs =j×L element +x0

[0077] y hs =k×L element +y0

[0078] z hs =-i×n w ×L element +d+z0

[0079] In this embodiment of the invention, the number of columns j in the current layer is multiplied by the cell size L. element This is the distance the heat source moves along the x-direction in the current layer, calculated as the layer number k multiplied by the cell size L. element This is the distance the heat source moves along the y-direction in the current layer. The total number of columns completed by additive manufacturing, i, multiplied by the distance (width W) of one column of additive manufacturing, is the total length of the completed column. The difference between this value and the total distance d that the heat source moves is exactly the distance the heat source moves along the z-axis in this column of additive manufacturing.

[0080] S4. Match the additive unit activation model and the heat source location model.

[0081] In this embodiment of the invention, the heat source movement velocity V from the heat source location model is used when constructing the additive unit activation model. hs Furthermore, when constructing the heat source location model, the relevant parameters in the additive unit activation model are also required. Therefore, by unifying the relevant basic parameters in the two models and adjusting the unit activation direction and the heat source movement direction, the matching between heat source movement and unit activation can be achieved.

[0082] S5. Using finite element software, perform heat conduction analysis on the matched additive unit activation model and heat source location model to obtain the temperature field distribution of the additive manufacturing process.

[0083] S6. Analyze the temperature field distribution, modify the parameters of the heat source location model based on the analysis results, improve the heat source location model, realize the simulation of electron beam additive manufacturing process, and improve the electron beam additive manufacturing process based on the simulation results.

[0084] Those skilled in the art will recognize that the embodiments described herein are intended to help the reader understand the principles of the invention, and should be understood that the scope of protection of the invention is not limited to such specific statements and embodiments. Those skilled in the art can make various other specific modifications and combinations based on the technical teachings disclosed in this invention without departing from the spirit of the invention, and these modifications and combinations are still within the scope of protection of this invention.

Claims

1. A simulation method for electron beam additive manufacturing process, characterized in that, Includes the following steps: S1. Based on the actual electron beam additive manufacturing process, determine the heat source moving speed and construct a cubic model of electron beam additive manufacturing; S2. Construct an additive unit activation model based on the heat source moving speed and the electron beam additive manufacturing cubic model; S3. Construct a heat source location model based on the heat source movement speed and the electron beam additive manufacturing cubic model; S4. Match the additive unit activation model and the heat source location model; S5. Use finite element software to perform heat conduction analysis on the matched additive unit activation model and heat source location model to obtain the temperature field distribution of the additive manufacturing process. S6. Analyze the temperature field distribution, modify the parameters of the heat source location model based on the analysis results, improve the heat source location model, realize the simulation of electron beam additive manufacturing process, and improve the electron beam additive manufacturing process based on the simulation results. In step S4, the heat source movement speed from the heat source location model is used when constructing the additive unit activation model. When constructing the heat source location model, the number of elements in the length direction of the cubic model in the additive manufacturing unit activation model is used. By unifying the relevant parameters in the two models and adjusting the activation direction of the unit and the movement direction of the heat source, the matching between the movement of the heat source and the activation of the unit is achieved.

2. The electron beam additive manufacturing process simulation method according to claim 1, characterized in that, The step S1 of constructing the electron beam additive manufacturing cubic model includes determining the length L, width W, height H, and cell size L of the cubic model. element And set the length L along the x-axis, the width W along the z-axis, and the height H along the y-axis.

3. The electron beam additive manufacturing process simulation method according to claim 2, characterized in that, Step S2 includes the following sub-steps: S21. Establish the additive unit activation sequence based on the heat source movement speed and the electron beam additive manufacturing cubic model: in , , These represent the number of elements in the length, width, and height directions of the cubic model, respectively. This indicates the time required to complete the additive manufacturing process for one cell. Indicates the speed at which the heat source moves; S22. Initialize and set the time. Additive manufacturing layer count y-axis direction parameters ; S23. Determine if the condition is satisfied. If yes, proceed to step S24; otherwise, proceed to step S3. S24. Set the number of cells for additive manufacturing. x-axis direction parameters ; S25. Determine if the condition is met. If yes, proceed to step S26; otherwise, reduce the number of additive manufacturing layers. Add 1, the y-axis direction parameter y increases by one cell size L. element Return to step S23; S26. Set the number of columns for additive manufacturing. z-axis direction parameters ; S27. Determine if the condition is met. If yes, proceed to step S28; otherwise, reduce the number of additive manufacturing cells. Add 1, the x-axis direction parameter x increases by one cell size L. element Return to step S25; S28, At time t, the activated coordinate is The cell at the location, and the number of additive manufacturing columns. Add 1, the z-axis direction parameter z increases by one cell size L. element Time t increases Return to step S27.

4. The electron beam additive manufacturing process simulation method according to claim 3, characterized in that, Step S3 includes the following sub-steps: S31. Calculate the time required to complete one train in additive manufacturing based on the heat source movement speed and the electron beam additive manufacturing cubic model. Time required to complete one layer of additive manufacturing : S32. Obtain the current time t and the initial position of the heat source. ; S33. Calculate the total distance d that the heat source has moved based on the current time t: S34. Calculate the total number of columns i completed in the additive manufacturing process, the number of columns j in the current layer during the additive manufacturing process, and the number of layers k during the additive manufacturing process based on the current time t: in This represents the floor function. This represents the function for finding the remainder. S35. Calculate the current location of the heat source. : 。

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