New Hammerstein Modeling and Analysis for Controlling Melt Pool Width in Powder Bed Fusion Additive Manufacturing
New Hammerstein Modeling and Analysis for Controlling Melt Pool Width in Powder Bed Fusion Additive Manufacturing
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DOI：
10.1115/1.4050079
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发表时间：
2021-07
期刊：
影响因子：
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通讯作者：
Dan Wang;Xinyu Zhao;Xu Chen
中科院分区：
文献类型：
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作者：
Dan Wang;Xinyu Zhao;Xu Chen
尽管有这些优点和新兴的应用，但更广泛地采用粉末床熔融（PBF）增材制造受到可靠性不足和过程中变化的挑战。有限元建模和面向控制的建模已被证明是有效的预测和工程零件质量的PBF。本文首先建立了一个有限元模型（FEM）的温度场研究过程中的复杂的热相互作用PBF。使用有限元数据，我们确定了一个新的代理系统模型，从激光功率的熔池宽度。将线性模型与无记忆非线性子模型相结合，我们开发了一个基于物理的Hammerstein模型，该模型捕获了复杂的时空热力学动力学。我们使用有限元方法验证了Hammerstein模型的准确性，并证明了线性化模型只是Hammerstein模型在平衡点附近的一个表示。沿着的方式，我们进行稳定性和鲁棒性分析和形式化的Hammerstein模型，以方便后续的控制设计。
Despite the advantages and emerging applications, broader adoption of powder bed fusion (PBF) additive manufacturing is challenged by insufficient reliability and in-process variations. Finite element modeling and control-oriented modeling have been shown to be effective for predicting and engineering part qualities in PBF. This paper first builds a finite element model (FEM) of the thermal fields to look into the convoluted thermal interactions during the PBF process. Using the FEM data, we identify a novel surrogate system model from the laser power to the melt pool width. Linking a linear model with a memoryless nonlinear submodel, we develop a physics-based Hammerstein model that captures the complex spatiotemporal thermomechanical dynamics. We verify the accuracy of the Hammerstein model using the FEM and prove that the linearized model is only a representation of the Hammerstein model around the equilibrium point. Along the way, we conduct the stability and robustness analyses and formalize the Hammerstein model to facilitate the subsequent control designs.