基于温度函数法的铝合金电弧增材制造残余应力与变形数值模拟
Numerical simulation on residual stress and deformation for WAAM parts of aluminum alloy based on temperature function method
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摘要: 电弧增材制造是制造大型复杂铝合金部件的新方法，但残余应力和变形对制造件的性能有重要影响. 建立了铝合金电弧增材制造件残余应力和变形的顺序热-力耦合有限元模型，采用移动热源法计算了增材过程的温度场，根据峰值温度的分布和演变特征确定了温度函数的提取方案，并分别采用移动热源法和温度函数法进行了残余应力和变形计算.结果表明，1段，3段，5段温度函数法分别将力学分析时间缩短91%，79%，63%，残余应力和基板变形误差均在20%以内，在满足计算精度的前提下显著提高了计算效率，为大型铝合金电弧增材制造件残余应力与变形的预测提供了途径.Abstract: Wire arc additive manufacture (WAAM) is a new way to fabricate large-scale complex aluminum alloy components, but the performance of the parts is critically influenced by residual stresses and deformation. A sequentially thermal-mechanical coupled model of residual stress and deformation for aluminum alloy WAAM parts was established based on commercial FE software ABAQUS. The temperature field was calculated by the moving heat source (MHS) method. The temperature function was obtained according to the distribution of the peak temperature. Furthermore, the MHS method and segmented temperature function (STF) method were used to calculate the residual stress and deformation. The results show that the STF method satisfies both the efficiency and accuracy requirements. 1-segment, 3-segment, and 5-segment STF methods can shorten the time for mechanical analysis by 91%, 79%, 63%, respectively. The error of the residual stress and deformation are all less than 20%. STF method provides an effective way to predict the residual stress and deformation of large-scale WAAM parts.
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