Efficient Simulation Methods for Thermal‐Mechanical Coupled Analysis and Rapid Residual Distortion Prediction of Laser Melting Deposition Process. Issue 8 (18th May 2021)

• Record Type: Journal Article
• Authors: Cao, Xiankun; Duan, Chenghong; Luo, Xiangpeng
• Is Part Of: Steel research international. Volume 92:Issue 8(2021)
• Page Start: n/a
• Page End: n/a
• Publication Date: 2021-05-18
• Subjects: improved thermal‐mechanical coupled simulations -- large-sized parts -- laser melting deposition -- multiscale methods -- residual distortions; Steel -- Periodicals; Steel -- Metallurgy -- Periodicals; 669.142
• DOI: 10.1002/srin.202000615
• Languages: English
• ISSNs: 1611-3683

Abstract

Abstract : Herein, an improved thermal‐mechanical coupled analysis is used to increase the calculation efficiency of the detailed laser melting deposition (LMD) process. By optimizing the loading process of the laser heat source and lumping several deposited layers into an equivalent numerical layer, the efficiency is significantly improved. The calculation time is saved by 85% when lumping six layers. Compared with the experimental data, the minimum deviation of predicted maximum distortion reaches 3.2% when lumping four layers. A multiscale method is proposed to predict the distortion result of the large‐sized part efficiently. In this method, the optimal heights of equivalent numerical layers are explored. The comparisons with the experimental result show that the optimal heights of equivalent numerical layers are 1 and 1.5 mm in view of accuracy and efficiency. Based on the multiscale method, the residual distortion of the substrate after depositing a large‐sized eight‐layer line deposition structure is accurately predicted. The deviations of the maximum distortion predicted by the improved thermal‐mechanical coupled simulation and the multiscale method are 3.26% and 6.12%, respectively. Moreover, the calculation time of the latter is 98.8% less than that of the former. Abstract : An improved thermal‐mechanical coupled simulation method and the multiscale method are proposed, respectively. The improved thermal‐mechanical coupled method accelerates the efficiency of the mechanism simulation of the laser melting deposition process, and the purpose of the multiscale method is to directly and efficiently obtain the residual distortion results of LMD large‐sized parts.