Control-Oriented Modeling and Repetitive Control in In-Layer and Cross-Layer Thermal Interactions in Selective Laser Sintering

Control-Oriented Modeling and Repetitive Control in In-Layer and Cross-Layer Thermal Interactions in Selective Laser Sintering
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选择性激光烧结中层内和跨层热相互作用的面向控制的建模和重复控制

DOI:
10.1115/1.4046367
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发表时间:
2021
期刊:
ASME Letters in Dynamic Systems and Control
影响因子:
--
通讯作者:
Chen, Xu
Chen, Xu
中科院分区:
--
文献类型:
--
作者:
Wang, Dan;Jiang, Tianyu;Chen, Xu

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尽管基于激光的增材制造 (AM) 已经实现了前所未有的直接从数字模型制造复杂零件的技术,但该技术的更广泛采用仍然面临着可靠性不足和过程中变化的挑战。为了确保选择性激光烧结(SLS)增材制造的质量,本文构建了激光源与待加工材料之间关键热力学相互作用的建模和控制框架。首先,我们开发了三维有限元模拟,以了解熔池演化的重要特征,以设计传感和反馈算法。我们探讨了温度场如何受到舱口间距和与温度相关的热属性的影响。基于高性能计算机模拟和实验,我们验证了重复的层内和层间热机械相互作用引起的周期性扰动的存在和影响。从那里,我们确定了从激光功率到熔池宽度的系统模型,并构建了重复控制算法以大大减弱熔池几何形状的变化。
Although laser-based additive manufacturing (AM) has enabled unprecedented fabrication of complex parts directly from digital models, broader adoption of the technology remains challenged by insufficient reliability and in-process variations. In pursuit of assuring quality in the selective laser sintering (SLS) AM, this paper builds a modeling and control framework of the key thermodynamic interactions between the laser source and the materials to be processed. First, we develop a three-dimensional finite element simulation to understand the important features of the melt pool evolution for designing sensing and feedback algorithms. We explore how the temperature field is affected by hatch spacing and thermal properties that are temperature-dependent. Based on high-performance computer simulation and experimentation, we then validate the existence and effect of periodic disturbances induced by the repetitive in- and cross-layer thermomechanical interactions. From there, we identify the system model from the laser power to the melt pool width and build a repetitive control algorithm to greatly attenuate variations of the melt pool geometry.
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