激光选区熔化单道扫描与搭接数值模拟及试验

doi:10.3901/JME.2020.22.056

机械工程学报 ›› 2020, Vol. 56 ›› Issue (22): 56-67.doi: 10.3901/JME.2020.22.056

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激光选区熔化单道扫描与搭接数值模拟及试验

梁平华^1,2, 唐倩¹, 冯琪翔¹, 宋军¹

1. 重庆大学机械传动国家重点实验室重庆 400044;
2. 中国科学院光电技术研究所成都 610209

收稿日期:2019-12-15 修回日期:2020-05-25 出版日期:2020-11-20 发布日期:2020-12-31
通讯作者: 唐倩(通信作者),女,1969年出生,博士,教授,博士研究生导师。主要研究方向为金属增材制造。E-mail:tqcqu@cqu.edu.cn
作者简介:梁平华,男,1994年出生。主要研究方向为激光选区熔化成形关键技术。E-mail:liangpinghua@cqu.edu.cn
基金资助:
国家自然科学基金（51975073，51805052）和重庆市技术创新与应用示范（cstc2018 jszx-cyzdX0102）资助项目。

Numerical Simulation and Experiment of Single Track Scanning and Lapping in Selective Laser Melting

LIANG Pinghua^1,2, TANG Qian¹, FENG Qixiang¹, SONG Jun¹

1. State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400044;
2. Institute of Optics and Electronics, Chinese Academy of Sciences, Chengdu 610209

Received:2019-12-15 Revised:2020-05-25 Online:2020-11-20 Published:2020-12-31

摘要/Abstract

摘要： 激光选区熔化（Selective laser melting，SLM）单道扫描的数值模拟，在数值建模时多采用规则实体模拟铺设的粉末层，通过等效定义材料热物理属性模拟铺设粉末层中粉末与气体共存的情况，难以模拟粉末颗粒的随机性而带来的扫描结果的随机性，且难以分析熔池形貌、内部缺陷的微观衍变过程。针对SLM成形过程中激光功率和单道搭接率对扫描单道和单道搭接质量的影响，以316L不锈钢材料为例，建立SLM首层单道扫描与单道搭接数值模拟模型。SLM的铺粉过程在基于离散单元法的EDEM中建立，并得到数值化的粉床几何模型。SLM的单道扫描与搭接的模拟基于有限体积法，在FLUENT中实现，采用两相流模型与熔化/凝固模型捕捉熔池形貌变化过程，得到不同激光功率和扫描搭接率下成形单道与单道搭接的数值模型。最后结合试验表明了在100~300 W激光功率下成形单道表面形貌与缺陷的形成，当激光功率为100~150 W时，单道形貌不规则，且容易形成局部缺陷；在200~300 W功率下，激光功率越大，保证搭接质量的最低搭接率越小，当激光功率为250 W时，应保证单道填充间距不大于0.1 mm。研究成果对SLM工艺参数的调整与优化具有重要的参考价值。

关键词: 激光选区融化, 数值模拟, 单道扫描, 搭接

Abstract: In the numerical simulation of selective laser melting(SLM) single track scanning, the geometrically regular solid model is often used to simulate the powder layer, and the coexistence of powder and gas in the powder layer is simulated by equivalent definition of material thermophysical properties. It is difficult to simulate the randomness of the scanning results caused by the randomness of powder particles, and it is difficult to analyze the shape and inner of the molten pool micro evolution process of micro defects. In view of the influence of laser power and lap ratio of single track on the quality of single track and lapping in SLM forming process, numerical simulation models of single track and the lapping of single track in the first layer process of SLM are established with 316L stainless steel as an example. The powder spreading process of SLM is established in EDEM based on the discrete element method, and the numerical powder bed geometry model is obtained. The simulation of SLM single pass scanning and lapping is based on the finite volume method, which is implemented in FLUENT. The two-phase flow model and the solidification/melting model are used to capture the changing process of the molten pool morphology, and the numerical models of single track and lapping of single track in different laser power and scanning lapping ratio are obtained. At last, the formation of the single track surface morphology and defects under the laser power of 100-300 W is illustrated. When the laser power is 100-150 W, the morphology of single track is irregular and easy to form local defects. When the laser power is 200-300 W, the higher the laser power is, the smaller the minimum lapping ratio is to ensure the lapping quality. When the laser power is 250 W, the single track filling spacing should be no more than 0.1 mm. The research results have important reference value for the adjustment and optimization of SLM process parameters.

Key words: selective laser melting, numerical simulation, single track scanning, lapping

中图分类号:

TG665

梁平华, 唐倩, 冯琪翔, 宋军. 激光选区熔化单道扫描与搭接数值模拟及试验[J]. 机械工程学报, 2020, 56(22): 56-67.

LIANG Pinghua, TANG Qian, FENG Qixiang, SONG Jun. Numerical Simulation and Experiment of Single Track Scanning and Lapping in Selective Laser Melting[J]. Journal of Mechanical Engineering, 2020, 56(22): 56-67.

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激光选区熔化单道扫描与搭接数值模拟及试验

Numerical Simulation and Experiment of Single Track Scanning and Lapping in Selective Laser Melting

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