高级检索

微重力激光熔丝金属增材制造数值方法

Numerical Method for Laser Wire Additive Manufacturing of Metals in Microgravity

  • 摘要: 针对微重力环境下激光熔丝金属增材制造过程中丝材持续送进与熔化行为难以准确模拟、熔池流动及沉积层形貌演化规律尚不明确的问题,建立了适用于微重力下激光熔丝金属增材制造过程的三维瞬态多物理场耦合模型。通过引入浸入式边界方法实现了丝材持续送入行为模拟,开展成形过程中丝材送进、熔化、液桥形成与熔池演化、熔池凝固等行为的数值模拟研究。针对复杂成形过程中的网格计算效率问题,提出了基于分区加密的网格处理方法,通过不同网格总数的算例计算,在保证计算精度的前提下显著提升了计算效率。模拟结果显示,成形过程中熔化的金属丝材主要由丝材端部向熔池尾部流去,并在熔池尾部凝固形成堆积体。目前工况下微重力熔池温度场分布及沉积层形貌与常重力环境下差异不显著。本研究为微重力环境下激光熔丝金属增材制造过程的数值模拟提供了有效方法,可为后续不同工况下的工艺调控及理论分析提供参考。

     

    Abstract: To address the challenges in accurately simulating continuous wire feeding and melting during laser wire additive manufacturing under microgravity, as well as the insufficient understanding of melt pool flow and deposit morphology evolution, a three-dimensional transient multiphysics coupling model was developed for this process. The immersed boundary method was introduced to simulate continuous wire feeding, enabling numerical investigation of wire feeding and melting, liquid bridge formation, melt pool evolution, and melt pool solidification. To improve computational efficiency in simulating the complex deposition process, a mesh treatment method based on zonal refinement was proposed. Simulations with different total numbers of mesh cells demonstrated that this strategy significantly improved computational efficiency while maintaining computational accuracy. The simulation results showed that the molten metal primarily flowed from the wire tip toward the rear of the melt pool, where it solidified to form the deposited material. Under the investigated conditions, no significant differences were observed in the melt pool temperature distribution or deposit morphology between microgravity and normal-gravity environments. This study provides an effective numerical approach for simulating laser wire additive manufacturing under microgravity and offers a reference for subsequent process control and theoretical analysis under different operating conditions.

     

/

返回文章
返回