A finite difference method for fast prediction and control of part-scale temperature evolution in laser powder bed fusion
A finite difference method for fast prediction and control of part-scale temperature evolution in laser powder bed fusion
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DOI：
10.1016/j.jmapro.2023.03.020
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发表时间：
2023-05
影响因子：
6.2
通讯作者：
Yong Ren;Qianqian Wang
中科院分区：
文献类型：
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作者：
Yong Ren;Qianqian Wang
零件尺度热模拟是激光粉末床熔化过程多尺度热力学分析的重要组成部分，是实现大尺寸零件热模拟计算效率的关键。本文提出了一种新的有限差分模型，可以提供快速预测的部分规模的温度演变，使基于模型的部分规模的热控制。所提出的建模方法的有效性说明通过案例研究的平方正则几何形状的Inconel 718，其中几个传热参数的模型通过匹配模型计算与现场测量的层间温度从构建过程中获得的EOS M280系统。模型计算的层间温度和测量温度的平均值之间的均方根误差小于25 °C，这表明一旦确定了模型参数，模型就捕获了层间温度预测的主要基础物理。建议的建模工作表明，零件组件和粉末床之间的热传递是必不可少的，以表征部分规模的温度演变。基于所提出的部分尺度热模型，数值研究了通过逐层控制激光功率来实现层间温度的最优控制。从这项研究的结果奠定了基础，为未来的实验研究，基于模型的部分规模的热控制，以减少过热，从而提高粉末床融合系统的构建质量。
Part-scale thermal modeling is a crucial building block in the multi-scale thermo-mechanical analysis for laser powder bed fusion process, and it plays a pivotal role in enabling computationally efficient thermal simulation of parts of large size. This paper presents a novel finite difference model that can provide fast prediction of part-scale temperature evolution to enable model-based part-scale thermal control. The effectiveness of the proposed modeling method is illustrated through a case study of a square-canonical geometry of Inconel 718, where several heat transfer parameters of the model are identified by matching the model computation with the in-situ measurements of interlayer temperature obtained from the build process on an EOS M280 system. The root-mean-square error between the model computed interlayer temperature and mean values of the measured temperature is less than 25 °C, suggesting that the model captures the major underlying physics for interlayer temperature prediction once the model parameters are identified. The proposed modeling efforts demonstrate that the heat transfer between part components and powder bed is essential to characterize part-scale temperature evolution. Based on the proposed part-scale thermal model, a numerical study on optimal control of interlayer temperature through layer-by-layer control of laser power is also presented. Results from this study set a foundation for future experimental investigation of model-based part-scale thermal control to reduce overheating by which to improve build quality for powder bed fusion systems.