Hybrid Powder Bed Fusion with Laser Forging for Support-Free Printing
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Solution Overview
Problem
Existing laser powder bed fusion technologies face challenges in effectively performing de-supporting forging printing on complex workpieces due to residual tensile stress causing deformation and cracking, which increases manufacturing time and cost, and compromises geometric freedom.
Innovation Solution
A method involving numerical simulation to identify stress field concentration areas, followed by ultrafast laser forging printing to reduce stress levels and minimize support requirements, using a system with a powder spreading device, powder bed laser, image monitoring, and ultrafast laser control to achieve additive manufacturing of complex structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large number of supports are used to prevent residual tensile stress from causing deformation and cracking, then component quality is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent applies preliminary action by performing numerical simulation before actual printing to identify stress field concentration areas. This allows pre-planning of support structures and printing parameters to prevent deformation and cracking from the outset, rather than dealing with defects after printing. The simulation-guided approach enables optimal support placement that minimizes both support quantity and manufacturing time while ensuring component quality.
Solution Approach 2:
The patent implements feedback through numerical simulation that analyzes stress field distribution during the printing process. The simulation results provide real-time feedback on stress concentration areas, allowing dynamic adjustment of printing parameters and support structures. This closed-loop control system enables optimization of support usage, reducing both manufacturing time and material waste while maintaining high component quality.
2Manufacturing precision
If a large number of supports are used to prevent residual tensile stress from causing deformation and cracking, then component quality is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies preliminary action by performing numerical simulation before actual printing to identify stress field concentration areas. This allows pre-planning of support structures and printing parameters to prevent deformation and cracking from the outset, rather than dealing with defects after printing. The simulation-guided approach enables optimal support placement that minimizes both support quantity and manufacturing time while ensuring component quality.
Solution Approach 2:
The patent implements feedback through numerical simulation that analyzes stress field distribution during the printing process. The simulation results provide real-time feedback on stress concentration areas, allowing dynamic adjustment of printing parameters and support structures. This closed-loop control system enables optimization of support usage, reducing both manufacturing time and material waste while maintaining high component quality.
3Adaptability or versatility
If supports are removed after printing, then geometric degree of freedom of workpieces is improved, but additional processing time and complexity are required
Solution Approach 1:
The patent applies the extraction principle by using numerical simulation to identify and extract only the essential support structures needed for printing stability. Rather than using excessive supports, the simulation identifies minimum necessary support locations and configurations. This reduces the amount of material that needs to be removed post-printing, saving time while maintaining geometric freedom of the final workpiece.
4Adaptability or versatility
If traditional laser powder bed fusion is used without stress field regulation, then printing process simplicity is maintained, but the types of printable components are limited
Solution Approach 1:
The patent applies preliminary action by performing numerical simulation before actual printing to identify stress field concentration areas. This allows pre-planning of support structures and printing parameters to prevent deformation and cracking from the outset, rather than dealing with defects after printing. The simulation-guided approach enables optimal support placement that minimizes both support quantity and manufacturing time while ensuring component quality.
Solution Approach 2:
The patent implements feedback through numerical simulation that analyzes stress field distribution during the printing process. The simulation results provide real-time feedback on stress concentration areas, allowing dynamic adjustment of printing parameters and support structures. This closed-loop control system enables optimization of support usage, reducing both manufacturing time and material waste while maintaining high component quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces the need for supports, decreases manufacturing time and cost, and enhances manufacturing flexibility by effectively managing stress fields in complex workpieces through targeted laser processing.
Implementation Method 1
controlling powder bed laser and ultrafast laser to perform forging printing on the workpiece to be printed according to corresponding laser parameters and scanning paths
Implementation Method 2
control the powder bed laser to fuse the metal powder
Implementation Method 3
obtain stress distribution data by performing different numbers of forging printing simulations on the stress field concentration area with ultrafast laser
Implementation Method 4
reduces the stress level... by effectively managing stress fields in complex workpieces through targeted laser processing
Data Source
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AI summary
The invention provide a de-supporting forging printing method, a de-supporting forging printing system, a de-supporting forging printing device, and a medium. The method includes: obtaining a stress field concentration area by simulating a stress field for a geometric model of a workpiece to be printed during a forging printing process through a numerical simulation method; obtaining stress distribution data by performing different numbers of forging printing simulations on the stress field concentration area with ultrafast laser under a de-supporting condition based on the numerical simulation method; selecting target stress distribution data from the stress distribution data according to a preset stress range, and determining a powder bed laser configuration parameter and an ultrafast laser configuration parameter according to the target stress distribution data; and controlling powder bed laser and ultrafast laser to perform forging printing on the workpiece to be printed according to corresponding laser parameters and scanning paths.