技术领域technical field
本发明属于增材制造领域，具体涉及一种超声冲击处理对激光选区熔化成形金属构件残余应力影响的分析方法。The invention belongs to the field of additive manufacturing, and in particular relates to an analysis method for the influence of ultrasonic impact treatment on the residual stress of a metal component formed by laser selective melting.
背景技术Background technique
铝合金具有良好的力学性能和加工性能，其密度较小、耐腐蚀耐磨性能好、强度和刚度高和抗冲击性能强等优点，在航空航天、汽车制造、船舶与海洋工程装备领域有着广泛的应用。激光选区熔化成形加工方式可以不受零件结构复杂程度的限制，制造出任意形状的构件。近年来，铝合金零部件激光选区熔化成形技术得到了越来越多的应用。Aluminum alloy has good mechanical properties and processing properties. It has the advantages of low density, good corrosion resistance and wear resistance, high strength and rigidity, and strong impact resistance. It has a wide range of applications in aerospace, automobile manufacturing, shipbuilding and marine engineering equipment. Applications. The laser selective melting forming processing method can produce components of any shape without being limited by the complexity of the part structure. In recent years, the laser selective melting forming technology of aluminum alloy parts has been more and more applied.
由于激光选区熔化成形加工方式在加工过程中持续的快速熔化和凝固的特点，加工后容易产生残余应力和变形。对于铝合金构件，其刚度较小，所以更容易发生变形、开裂等，严重抑制了激光选区熔化成形技术在制造大尺寸构件上的应用。因此，有效的后处理技术控制构件的残余应力和提高表面质量具有重要意义。超声冲击技术是通过高频机械冲击的方式处理零件的表面，将其表面原有的拉应力转变为对构件有益的压应力、提高疲劳寿命，并且具有设备体积小、操作简单、适用性强等优点。作为一种有效的后处理技术，被广泛应用。Due to the continuous and rapid melting and solidification characteristics of laser selective melting forming during processing, residual stress and deformation are prone to occur after processing. For aluminum alloy components, their rigidity is small, so deformation, cracking, etc. are more likely to occur, which seriously inhibits the application of laser selective melting forming technology in the manufacture of large-scale components. Therefore, effective post-processing technology is of great significance to control the residual stress of components and improve the surface quality. Ultrasonic impact technology treats the surface of parts by means of high-frequency mechanical impact, transforms the original tensile stress on the surface into compressive stress that is beneficial to components, improves fatigue life, and has the advantages of small equipment, simple operation, and strong applicability, etc. advantage. As an effective post-processing technique, it is widely used.
但是由于超声冲击过程机理十分复杂，这就造成了很难对其工艺参数进行优化。单纯依靠实验数据和操作经验的方式会浪费大量的人力、物力与时间。However, due to the complex mechanism of the ultrasonic shock process, it is difficult to optimize its process parameters. Simply relying on experimental data and operating experience will waste a lot of manpower, material resources and time.
目前有很多专家和学者进行了超声冲击对构件内部残余应力影响的模拟分析工作。但是很少有对超声冲击对于激光选区熔化增材制造构件残余应力的模拟分析。这种模拟分析必须建立在激光选区熔化成形构件的残余应力和变形的基础上进行研究。目前的模拟分析一般不考虑初始应力和变形的影响。关于激光选区熔化成形宏观构件的模拟，必须应用特定的增材制造模拟软件方可进行。目前常用来模拟超声过程的有限元软件为ANSYS/LS-DYNA/ABAQUS和Msc.Marc。但只有Msc.Marc可以读入Simufact.additive软件分析的残余应力场与变形。At present, many experts and scholars have carried out the simulation analysis of the influence of ultrasonic impact on the internal residual stress of components. However, there are few simulations and analyzes of ultrasonic impact on the residual stress of laser selective melting additive manufacturing components. This kind of simulation analysis must be based on the research on the residual stress and deformation of laser selective melting forming components. The current simulation analysis generally does not consider the influence of initial stress and deformation. For the simulation of laser selective melting forming macroscopic components, specific additive manufacturing simulation software must be used. The finite element software commonly used to simulate the ultrasonic process is ANSYS/LS-DYNA/ABAQUS and Msc.Marc. But only Msc.Marc can read the residual stress field and deformation analyzed by Simufact.additive software.
发明内容Contents of the invention
本发明的目的在于提供一种超声冲击处理对激光选区熔化成形金属构件残余应力影响的分析方法，能够实现优化冲击工艺参数和探究其作用机理的目的。The purpose of the present invention is to provide an analysis method for the influence of ultrasonic impact treatment on the residual stress of metal components formed by laser selective melting, which can achieve the purpose of optimizing impact process parameters and exploring its mechanism of action.
一种超声冲击处理对激光选区熔化成形金属构件残余应力影响的分析方法，具体包括如下步骤：A method for analyzing the influence of ultrasonic impact treatment on the residual stress of metal components formed by laser selective melting, which specifically includes the following steps:
步骤1：首先采用有限元软件Simufact.Additive对激光选区熔化成形过程进行模拟，获得残余应力场和变形，并且读入到Simufact.Forming中进行冷却至室温，获得稳定的残余应力场和变形。Step 1: First, use the finite element software Simufact.Additive to simulate the laser selective melting forming process to obtain the residual stress field and deformation, and read it into Simufact.Forming to cool to room temperature to obtain a stable residual stress field and deformation.
步骤2、采用多步计算的方式，先在Msc.Marc中读入变形几何体，然后重新打开文件，将激光选区熔化成形构件的残余应力按着节点和网格设置为初始条件，随后进行超声冲击模拟分析计算。Step 2. Using a multi-step calculation method, first read the deformed geometry in Msc.Marc, then reopen the file, set the residual stress of the laser selective melting forming component as the initial condition according to the node and grid, and then perform ultrasonic shock Simulation analysis calculation.
步骤3、在Msc.Marc软件中建立超声冲击模型，然后将激光选区熔化成形获得的应力场作为分析的初始状态，进行超声冲击对激光选区熔化成形金属构件残余应力场作用的过程模拟分析。Step 3. Establish an ultrasonic impact model in the Msc.Marc software, and then use the stress field obtained by laser selective melting forming as the initial state of analysis, and conduct a process simulation analysis of the effect of ultrasonic shock on the residual stress field of laser selective melting forming metal components.
所述一种超声冲击处理对激光选区熔化成形金属构件残余应力影响的分析方法，步骤2具体包括如下步骤：In the method for analyzing the influence of ultrasonic impact treatment on the residual stress of metal components formed by selective laser melting, step 2 specifically includes the following steps:
步骤2.1、激光选区熔化成形过程模拟，首先读入构件三维模型到Simufact.Additive，添加支撑和加工参数，进行激光选区熔化成形过程模拟，获得带有应力场和变形几何模型的结果文件；Step 2.1, simulation of the laser selective melting forming process, first read the 3D model of the component into Simufact.Additive, add support and processing parameters, perform the simulation of the laser selective melting forming process, and obtain the result file with the stress field and deformation geometric model;
步骤2.2、过渡步计算，将在Simufact.Additive计算得出的结果文件的应力场和变形几何体导入到Simufact.Forming中，并重新赋予相同的材料属性，进行冷却处理，冷却到室温25℃，获得冷却之后的应力场和变形几何模型的结果文件。Step 2.2, transition step calculation, import the stress field and deformation geometry of the result file calculated in Simufact.Additive into Simufact.Forming, and re-assign the same material properties, perform cooling treatment, cool to room temperature 25°C, and obtain Results file of the stress field and deformation geometry after cooling.
所述一种超声冲击处理对激光选区熔化成形金属构件残余应力影响的分析方法，MSC.Marc模拟中同一位置多次冲击与现实实验中全覆盖冲击的对应法则是根据实验中超声冲击设备的移动速度来建立的。The method for analyzing the influence of ultrasonic impact treatment on the residual stress of laser selective melting and forming metal components, the correspondence rule between multiple impacts at the same position in MSC.Marc simulation and full-coverage impacts in real experiments is based on the movement of ultrasonic impact equipment in experiments speed to build.
所述一种超声冲击处理对激光选区熔化成形金属构件残余应力影响的分析方法，超声冲击过程采用隐式求解器。The method for analyzing the influence of ultrasonic impact treatment on the residual stress of metal components formed by laser selective melting, uses an implicit solver for the ultrasonic impact process.
所述一种超声冲击处理对激光选区熔化成形金属构件残余应力影响的分析方法，所述超声冲击技术的基本原理是磁致伸缩式或压电晶体式换能器将高频交变电能转换为机械能，换能器的震动输出端部与变幅杆相连，变幅杆另一端部与冲击针有一定的空隙，当换能器在高频交变电能输入时换能器做小振幅纵向往复运动，变幅杆将振幅放大从而撞击冲击针，从而冲击针高速向前冲击，在撞击到工件表面后开始回弹，如此在变幅杆和工件之间多次快速反复运动，从而完成对工件表面的处理，改变其原有的应力分布，引入对构件有益的压应力。The method for analyzing the influence of ultrasonic shock treatment on the residual stress of laser selective melting and forming metal components, the basic principle of the ultrasonic shock technology is that a magnetostrictive or piezoelectric crystal transducer converts high-frequency alternating electric energy into Mechanical energy, the vibration output end of the transducer is connected to the horn, and there is a certain gap between the other end of the horn and the impact needle. When the transducer is input with high-frequency alternating electric energy, the transducer performs small-amplitude longitudinal reciprocation Movement, the horn amplifies the amplitude to hit the impact needle, so the impact needle strikes forward at high speed, and starts to rebound after hitting the surface of the workpiece, so it moves repeatedly and quickly between the horn and the workpiece to complete the workpiece Surface treatment changes its original stress distribution and introduces compressive stress beneficial to components.
本发明的有益效果在于：The beneficial effects of the present invention are:
本发明利用Msc.Marc动力瞬态模块进行超声冲击的模拟，将激光选区熔化成形应力场作为初始条件，计算结果与残余应力测试仪测设结果在数值与变化趋势上具有很好的一致，实现了优化冲击工艺参数和探究其作用机理的目的。The invention utilizes the Msc.Marc dynamic transient module to simulate the ultrasonic impact, and takes the stress field of the laser selective melting forming as the initial condition, and the calculation result is in good agreement with the measurement result of the residual stress tester in terms of value and change trend, realizing In order to optimize the impact process parameters and explore its mechanism of action.
附图说明Description of drawings
图1为被冲击构件有限元网格划分图；Figure 1 is the finite element mesh division diagram of the impacted member;
图2为冲头、冲击针与被冲击构件划分网格后整体装配图；Figure 2 is the overall assembly diagram of the punch, the impact needle and the impacted member after meshing;
图3为加载在冲头上的位移载荷曲线；Fig. 3 is the displacement load curve loaded on the punch;
图4为激光选区熔化成形后构件沿中心线纵向截面切开横向方向位移图；Fig. 4 is a lateral direction displacement diagram of the member cut along the longitudinal section of the center line after selective laser melting and forming;
图5为激光选区熔化成形后构件沿中心线纵向截面切开后横向应力分布；Fig. 5 shows the transverse stress distribution after the component is cut along the longitudinal section of the centerline after selective laser melting;
图6为冲击处理过后构件沿中心线纵向截面切开后横向应力分布；Fig. 6 shows the transverse stress distribution of the component after impact treatment after being cut along the longitudinal section of the center line;
图7为冲击处理过后构件沿中心线纵向截面切开后横向位移分布。Fig. 7 shows the lateral displacement distribution of the component after impact treatment after being cut along the longitudinal section of the center line.
具体实施方式Detailed ways
下面结合附图对本发明做进一步描述。The present invention will be further described below in conjunction with the accompanying drawings.
图1为被冲击构件有限元网格划分图；图2为冲头、冲击针与被冲击构件划分网格后整体装配图；图3为加载在冲头上的位移载荷曲线；图4为激光选区熔化成形后构件沿中心线纵向截面切开横向方向位移图；图5为激光选区熔化成形后构件沿中心线纵向截面切开后横向应力分布；图6为冲击处理过后构件沿中心线纵向截面切开后横向应力分布；图7为冲击处理过后构件沿中心线纵向截面切开后横向位移分布。Figure 1 is the finite element mesh division diagram of the impacted component; Figure 2 is the overall assembly diagram after meshing the punch, the impact needle and the impacted component; Figure 3 is the displacement load curve loaded on the punch; Figure 4 is the laser Displacement diagram in the transverse direction of the member cut along the longitudinal section of the centerline after selective melting and forming; Fig. 5 is the transverse stress distribution of the member after cutting along the longitudinal section of the centerline after selective melting and forming; Fig. 6 is the longitudinal section of the member after impact treatment Lateral stress distribution after cutting; Figure 7 shows the lateral displacement distribution after impact treatment after the longitudinal section of the member is cut along the center line.
首先是激光选区熔化成形过程的模拟。The first is the simulation of laser selective melting forming process.
步骤1、建立几何模型：尺寸12mm×12mm×5mm，并导入Simufact.Additve。利用Simufact.Additive软件中的金属粉末材料库定义其材料为AlSi10Mg粉末。Step 1. Establish a geometric model: the size is 12mm×12mm×5mm, and import it into Simufact.Additve. Use the metal powder material library in Simufact.Additive software to define its material as AlSi10Mg powder.
步骤2、添加支撑和切割方式以及设置计算结束后将所有支撑移除。Step 2. Add supports and cutting methods and set all supports after the calculation is completed.
步骤3、设置加工参数：激光功率200w、效率50％、光斑直径70um、扫描速度1.8m/s、加工层厚0.03mm，以及扫描策略为每次旋转670。Step 3. Set processing parameters: laser power 200w, efficiency 50%, spot diameter 70um, scanning speed 1.8m/s, processing layer thickness 0.03mm, and scanning strategy 670 per rotation.
步骤4、划分网格，单元尺寸为0.2mm。提交计算得出残余应力场和整体塑性应变。Step 4. Divide the grid, and the cell size is 0.2mm. Submit calculations to derive residual stress fields and global plastic strains.
冷却过程模拟。Simulation of the cooling process.
步骤1、在Simufact.Forming中导入结果文件获取几何模型和残余应力场。Step 1. Import the result file in Simufact.Forming to obtain the geometric model and residual stress field.
步骤2、重新赋予构件AlSi10Mg材料。Step 2. Re-assign the AlSi10Mg material to the component.
步骤3、增加冷却分析步，设置构件初始温度为50℃，环境温度为25℃。Step 3. Add a cooling analysis step, set the initial component temperature to 50°C, and the ambient temperature to 25°C.
步骤4、提交分析，获得稳定的带有应力场的整体塑性变形几何体的结果文件。Step 4. Submit the analysis to obtain a stable result file of the overall plastically deformed geometry with the stress field.
在以上基础上进行超声冲击对激光选区有限元残余应力场影响的数值模拟。具体过程如下所述：On the basis of the above, the numerical simulation of the effect of ultrasonic shock on the residual stress field of laser selected finite element is carried out. The specific process is as follows:
有限元模型和网格的划分：有限元模型包括被冲击构件、冲击针和冲头三个部分。被冲击构件网格直接导入变形网格，冲击针与冲头按照实际尺寸进行建模，设置为变形体，采用四面体网格对冲击针与冲头进行网格划分，读入变形网格的被加工构件以及划分过网格的冲击针与冲头模型如图2所示。Finite element model and grid division: The finite element model includes three parts: the impacted member, the impact needle and the punch. The grid of the impacted member is directly imported into the deformed grid, the impact pin and the punch are modeled according to the actual size, set as a deformed body, the tetrahedral grid is used to mesh the impact pin and the punch, and the deformed grid is read. The model of the machined component and the meshed impact needle and punch is shown in Figure 2.
材料属性：冲击针为钢，采用普通Q235钢的属性，输入密度、弹性模量和泊松比；冲头为钨钢，采用普通YG28钢的属性，输入密度、弹性模量和泊松比；被冲击构件，利用弹性模量测量仪测量其弹性模量和泊松比，并测量其密度。对于被冲击构件，由于冲击针与构件之间作用属于高速非线性碰撞过程，构件的材料属性要考虑到加工硬化、应变率效应和温度软化效应。本文采用Johnson-cook模型来描述AlSi10Mg的动态本构关系，公式①为该模型的表达式，它反应上述因素对应力的影响，在MSC.MARC中有关于本模型的设置。Material properties: the impact pin is steel, adopt the properties of ordinary Q235 steel, input the density, elastic modulus and Poisson's ratio; the punch is made of tungsten steel, adopt the properties of ordinary YG28 steel, input the density, elastic modulus and Poisson's ratio; For components, measure their modulus of elasticity and Poisson's ratio with an elastic modulus measuring instrument, and measure their density. For the impacted component, since the impact between the impact needle and the component is a high-speed nonlinear collision process, the material properties of the component should take into account work hardening, strain rate effect and temperature softening effect. In this paper, the Johnson-cook model is used to describe the dynamic constitutive relation of AlSi10Mg. Formula ① is the expression of the model, which reflects the influence of the above factors on the stress. There are settings for this model in MSC.MARC.
σ-应力，ε-塑性应变，-应变率，-参考应变率，T-温度，Tr为参考温度，Tm是材料熔点温度。A、B、n、C、m－分别表示初始屈服强度、应变强化指数、应变率敏感系数、硬化指数和温度软化指数。σ-stress, ε-plastic strain, -Strain rate, - reference strain rate, T - temperature, Tr is the reference temperature, Tm is the melting point temperature of the material. A, B, n, C, m - represent the initial yield strength, strain hardening index, strain rate sensitivity coefficient, hardening index and temperature softening index, respectively.
本文通过实验取A＝578Mpa，B＝1509Mpa，n＝0.928，C＝0.0375，m＝0.94，Tr＝298.15k，Tm＝933.15k，In this paper, A=578Mpa, B=1509Mpa, n=0.928, C=0.0375, m=0.94, Tr=298.15k, Tm=933.15k,
接触设置；由于冲击过程中被冲击构件与冲击针和冲头之间有碰撞，所以设置被冲击构件与冲击针和冲头与冲击针双边动态面—面接触。冲击针与试件之间摩擦系数设置为0.5。Contact setting: Since there is collision between the impacted member and the impact pin and the punch during the impact, the impacted member is set to be in dynamic surface-to-surface contact with the impact pin and the punch and the impact pin. The coefficient of friction between the impact needle and the specimen was set to 0.5.
载荷和边界条件的设置Setup of Loads and Boundary Conditions
在表格模块建立其位移表格，如图3所示，将激光选区熔化成形残余应力作为前一个分析状态作为初始应力场，将建立好的位移表格设置为冲头垂直于被冲击构件方向上的位移边界条件，限制冲击针除冲击运动方向所有自由度，并添加位移约束在被冲击构件的底面节点，限制其运动。Create its displacement table in the table module, as shown in Figure 3, take the residual stress of laser selective melting forming as the previous analysis state as the initial stress field, and set the established displacement table as the displacement of the punch perpendicular to the direction of the impacted member Boundary conditions limit all degrees of freedom of the impact pin except the direction of impact motion, and add displacement constraints to the bottom surface nodes of the impacted member to limit its motion.
建立动力瞬态分析工况。Create a dynamic transient analysis case.
提交分析作业及后处理：完程有限元计算，得到全部超声冲击对激光选区熔化成形构件处理后的计算结果，包括应力、位移等，如图6、7所示，也可以进行进一步处理。Submit the analysis work and post-processing: complete the finite element calculation, and obtain the calculation results of all ultrasonic shocks on the laser selective melting and forming components, including stress, displacement, etc., as shown in Figures 6 and 7, and can also be further processed.
经过与实验结果比对，具有很好一致。本发明是对一种对超声冲击处理准确有效的模拟分析方法，对于优化超声冲击工艺参数和探究其作用机理具有重要的意义。After comparing with the experimental results, it is in good agreement. The invention is an accurate and effective simulation analysis method for ultrasonic shock treatment, and has important significance for optimizing ultrasonic shock process parameters and exploring its mechanism of action.
以上是对本发明的示例性描述，应该说明的是，在不脱离本发明核心的情况下，任何简单的修改和变形或者其他本领域技术人员能够不花费创造性劳动的等同替换均落入本发明的保护范围。The above is an exemplary description of the present invention, and it should be noted that, without departing from the core of the present invention, any simple modification and deformation or other equivalent replacements that those skilled in the art can do without spending creative labor all fall into the scope of the present invention. protected range.
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| CN201811031831.XACN108984984B (en) | 2018-09-05 | 2018-09-05 | A method for analyzing the effect of ultrasonic impact treatment on residual stress of metal components formed by laser selective melting |
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| CN109735843A (en)* | 2019-03-21 | 2019-05-10 | 株洲辉锐增材制造技术有限公司 | It is a kind of increase laser melting coating high hardness alloy thickness degree process and its laser melting coating reparation product |
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