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增减材复合制造模拟仿真及应力与变形演变规律

陈树君, 倪庆冕, 刘海滨, 陈平平, 闫朝阳, 谢瑞山

陈树君, 倪庆冕, 刘海滨, 陈平平, 闫朝阳, 谢瑞山. 增减材复合制造模拟仿真及应力与变形演变规律[J]. 焊接学报, 2025, 46(5): 1-9. DOI: 10.12073/j.hjxb.20240131002
引用本文: 陈树君, 倪庆冕, 刘海滨, 陈平平, 闫朝阳, 谢瑞山. 增减材复合制造模拟仿真及应力与变形演变规律[J]. 焊接学报, 2025, 46(5): 1-9. DOI: 10.12073/j.hjxb.20240131002
CHEN Shujun, NI Qingmian, LIU Haibin, CHEN Pingping, YAN Chaoyang, XIE Ruishan. Numerical simulation of hybrid additive and subtractive manufacturing and evolution behavior of stress and deformation[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2025, 46(5): 1-9. DOI: 10.12073/j.hjxb.20240131002
Citation: CHEN Shujun, NI Qingmian, LIU Haibin, CHEN Pingping, YAN Chaoyang, XIE Ruishan. Numerical simulation of hybrid additive and subtractive manufacturing and evolution behavior of stress and deformation[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2025, 46(5): 1-9. DOI: 10.12073/j.hjxb.20240131002

增减材复合制造模拟仿真及应力与变形演变规律

基金项目: 

国防基础科研项目(JCKY2022405C002);中国航空基金(20240011075001);国家自然科学基金资助项目 (52275299);重庆市自然科学基金(CSTB2023NSCQ-MSX0701)

详细信息
    作者简介:

    陈树君,博士,教授,博士研究生导师;主要从事焊接与增材制造工艺及智能装备领域的研究;Email: sjchen@bjut.edu.cn

    通讯作者:

    谢瑞山,博士,副研究员; Email: xiers@bjut.edu.cn.

  • 中图分类号: TG 444

Numerical simulation of hybrid additive and subtractive manufacturing and evolution behavior of stress and deformation

  • 摘要:

    增材制造构件的最终成形精度不仅取决于增材过程中的应力累积及宏观变形,而且和减材过程中的应力释放与再分布有重要的关系.为此,建立了增减材复合制造的联合模拟仿真方法,阐明了增材制造过程中的应力累积行为,及其在后续减材过程应力释放及二次变形规律.结果表明,电弧增材制造过程中在成形的最初几层以及最后的冷却阶段在零件和基板的交界位置处于三向拉应力;在铣削减材过程中,增材制造的残余应力逐渐释放并重新分布,最大残余应力的位置改变并且拉应力减小,同时在铣削过程中零件发生二次变形,零件两端变形量大而中间变形量小.文中提出的增减材联合仿真方法对最终成形零件的变形调控提供理论指导.

    Abstract:

    The final forming accuracy of additive manufacturing components depends not only on the stress accumulation and deformation during the additive manufacturing process, but also on the stress release and redistribution during milling.Therefore, a joint simulation method of hybrid additive and subtractive manufacturing was established, and the stress accumulation behavior in the process of additive manufacturing and its stress release and secondary deformation law in the subsequent material removal process were expounded. The results show that, in the process of arc additive manufacturing, there is a three-dimensional tensile stress at the interface between the part and the substrate in the first few layers and the final cooling stage. In the process of milling additive manufacturing, the residual stress is gradually released and redistributed, and the position of the maximum residual stress changes and the tensile stress decreases. At the same time, in the process of milling, the part undergoes secondary deformation, with large deformation at both ends and small deformation in the middle. The joint simulation method of hybrid additive and subtractive manufacturing proposed in this paper provides theoretical guidance for the deformation control of the final formed part.

  • 图  1   电弧增材单壁结构有限元模型(mm)

    Figure  1.   WAAM finite element model (mm)

    图  2   铣削过程建模

    Figure  2.   Modeling of milling process

    图  3   A点与B点温度循环曲线及测量样件

    Figure  3.   Temperature cycle curves and measurement samples at point A and point B. (a) measurement sampies; (b) location of temperrature testing; (c) temperature cycle of A; (d) temperature cycle of B

    图  4   残余应力测试点与沉积路径

    Figure  4.   Residual stress testing point and deposition path. (a) location of testing point; (b) deposition path; (c) schematic diagram of the path for extracting simulation

    图  5   沿Path3的残余应力分布

    Figure  5.   Residual stress distribution along Path3. (a) longitudinal residual stress; (b) horizontal residual stress

    图  6   增材过程中纵向应力演化图

    Figure  6.   Longitudinal stress evolution diagram during additive manufacturing. (a) first floor; (b) fifth floor; (c) tenth floor; (d) moment of final cooling

    图  7   减材加工过程中纵向残余应力的演化过程云图

    Figure  7.   Evolution of longitudinal residual stress during milling. (a) 0; (b) 5 s; (c) 10 s; (d) 20 s

    图  8   减材加工过程中纵向残余应力的演化过程曲线

    Figure  8.   Evolution curve of longitudinal residual stress during milling

    图  9   铣削减材过程中薄壁零件的二次变形云图

    Figure  9.   Deformation of parts during milling. (a) 0; (b) 5 s;(c) 10 s; (d) 20 s

    图  10   铣削减材过程中薄壁零件的二次变形曲线

    Figure  10.   Secondary deformation curve of parts during milling

    表  1   6061铝合金材料参数

    Table  1   Material properties of 6061 aluminum alloy

    温度
    T/K
    比热容
    c/(J·kg−1·℃−1)
    传导率
    λ/(W·m−1·℃−1)
    膨胀系数
    aj/10−5 K−1
    弹性系数
    E/GPa
    塑性系数
    R/MPa
    293 728 176 2.22 71 300
    373 795 180 2.38 65 284
    573 963 188 2.53 49 100
    773 1290 198 2.69 40 30
    973 1580 200 3.02 28 10
    下载: 导出CSV

    表  2   6061铝合金J-C模型参数

    Table  2   Johnson-Cook plasticity model parameters for 6061 alumimum alloy

    屈服强度
    Rel/MPa
    硬化模量
    ε/MPa
    C n m $ {\varepsilon }_{0} $ 熔点
    TC/K
    室温
    T/K
    324 114 0.0128 0.42 1.34 1 893 293
    下载: 导出CSV

    表  3   6061铝合金J-C失效模型参数

    Table  3   Johnson-Cook damage model parameters for 6061 aluminum alloy

    $ {d}_{1} $ $ {d}_{2} $ $ {d}_{3} $ $ {d}_{4} $ $ {d}_{5} $ $ {\varepsilon }_{0} $ 熔点TC/K 室温T/K
    −0.77 1.45 −0.47 0 1.6 1 893 293
    下载: 导出CSV
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出版历程
  • 收稿日期:  2024-01-30
  • 网络出版日期:  2025-05-05
  • 刊出日期:  2025-05-24

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