Open AccessEfficient Distortion Prediction of Laser Melting Deposited Industrial-scale Parts Using Modified Inherent Strain Method
Author(s) -
Chao Duan,
Xiankun Cao,
Xiao Luo
Publication year - 2021
Publication title -
iop conference series. earth and environmental science
Language(s) - English
Resource type - Journals
eISSN - 1755-1307
pISSN - 1755-1315
DOI - 10.1088/1755-1315/714/3/032032
Subject(s) - distortion (music) , camshaft , materials science , residual , scale (ratio) , structural engineering , computer science , mechanical engineering , algorithm , engineering , physics , amplifier , optoelectronics , cmos , quantum mechanics
As a result of the large temperature gradients, residual distortion becomes a major technical challenge for laser powder-based Laser Melting Deposition (LMD) process, since excessive distortion may cause building failure, cracks and loss in structural integrity. In this paper, the theory of a modified inherent strain method is firstly developed. On the basic of this method, the prediction results of a small-scale model are compared with those obtained from the traditional thermo-mechanical coupled analysis. The deviation of the maximum distortion predicted by the modified inherent strain method is 7.72%, and the average deviation of the distortion of the substrate’s free end is 8.73%, demonstrating a good accuracy (< 10% error) of the modified method for predicting the residual distortion of the LMD components. Compared to a small loss of accuracy, the calculation time is significantly shortened by the modified inherent strain method. After verification, the distortion prediction of industrial-scale camshaft model during LMD process is realized by using the proposed method. It is found that the maximum distortion is 3.18mm, located at both sides of the camshaft. After the support is removed, the two ends of the camshaft are warped upward, while the position of the maximum distortion doesn’t change, but the value increased to 4.62mm. Moreover, the whole analysis takes only 3300 seconds, which is extremely significant for the distortion prediction for industrial-scale parts fabricated by LMD.