电弧增材框体结构有限元仿真模拟与实验

doi:10.12382/bgxb.2024.0629

摘要/Abstract

摘要：

利用瞬态热源、热循环曲线、全热循环、固有应变4种算法,依次对电弧增材典型框体构件变形和应力进行模拟,分析不同算法下的预测精度与计算效率。研究结果表明:瞬态热源算法预测的最大变形位置为框体顶部4个边角处,应力主要集中分布在框体拐角及顶部区域,与实验结果吻合良好,特征点变形与应力的预测精度分别为96.59%与95.01%,计算时间为326h;热循环曲线算法的预测精度与瞬态热源算法相当,但计算时间缩短至117h,预测的变形云图及应力曲线与实验结果吻合较好;相较于前两种算法,全热循环和固有应变算法对特征点变形的预测精度较低,分别为85.68%和65.86%,预测的变形云图与实验结果存在较大差异,可信度较低,但计算时间分别缩短至4h和2h,效率显著提高。

关键词: 电弧增材, 数值模拟, 变形, 应力

Abstract:

The deformation and stress of typical additively manufactured frame components are simulated by using transient heat source algorithm,thermal cycle curve algorithm,full thermal cycle algorithm and intrinsic strain algorithm,and the prediction accuracies and calculation efficiencies of the different algorithms are analyzed.The results show that the maximum deformation position predicted by the transient heat source algorithm is the top four corners of the frame,and the stress is mainly distributed in the corners and top areas of the frame,which is in good agreement with the experimental results,and the prediction accuracies of feature point deformation and stress are 96.59% and 95.01%,respectively,and the calculation time is 326h;The prediction accuracy of the thermal cycle curve algorithm is comparable to that of the transient heat source algorithm,but the calculation time is shortened to 117h,and the predicted deformation contour and stress curve are in good agreement with the experimental results.Compared with the first two algorithms,the prediction accuracies of the full thermal cycle and intrinsic strain algorithms for feature point deformation are 85.68% and 65.86%,respectively,and the predicted deformation contour is quite different from the experimental results.The reliabilityies of the full thermal cycle and intrinsic strain algorithms are low,but their calculation times are shortened to 4h and 2h,respectively,and their efficiencies are significantly improved.

Key words: wire arc additive manufacturing, numerical simulation, deformation, stress

中图分类号:

TG456.7

李青松, 王磊, 赵宁, 张笑天, 张磊, 王克鸿. 电弧增材框体结构有限元仿真模拟与实验[J]. 兵工学报, 2025, 46(7): 240629-.

LI Qingsong, WANG Lei, ZHAO Ning, ZHANG Xiaotian, ZHANG Lei, WANG Kehong. Finite Element Simulation Analysis and Experimental Study of Arc Additive Frame Structure[J]. Acta Armamentarii, 2025, 46(7): 240629-.

图/表 19

图1 WAAM系统

Fig.1 WAAM system

表1 焊丝和基板的化学成分

Table 1 Chemical composition of welding wire and substrate

名称	Ni	Cr	C	Mn	Si	P	Fe
焊丝		18.8	0.019	1.93	0.581	0.024	Bal.
基板	8.11	18.18	0.05	0.74	0.36	0.021	Bal.

图2 框体增材实验示意图

Fig.2 Schematic diagram of the frame additive experiment

图3 框体增材有限元模型

Fig.3 Frame additive finite element model

表2 304不锈钢力学性能[18]

Table 2 Mechanical properties of 304 stainless steel[18]

温度/ ℃	屈服强度/ MPa	热膨胀系数/ 10^-5℃^-1	杨氏模量/ GPa	泊松比
20	254	1.45	194	0.29
100	245	1.56	185
200	187	1.66	171
300	174	1.74	168
400	166	1.78	162
600	158	1.87	90
800	109	1.92	66
1000	57	1.97	43
1200	25	2.01	20
1500	10	2.16	10

表3 304不锈钢热物理参数[19]

Table 3 Thermo-physical parameters of 304 stainless steel[19]

温度/ ℃	比热容/ (J·kg^-1·K^-1)	热导率 (W·m^-1·K^-1)	密度/ (g·cm^-3)	弹性模量/GPa	线膨胀系数/ 10^-6K^-1
25	450	7.77	16.71	208.46	13.61
400	610	7.64	21.42	180.92	14.26
800	670	7.48	26.40	138.00	16.35
1000	670	7.40	28.94	113.25	17.07
1200	700	7.31	31.36	0.80	17.77
1400	1490	7.19	33.49	44.68	19.64
1450	9260	7.01	30.79	0	25.30
1500	810	6.69	31.48	0	25.78

图4 双椭球热源模型

Fig.4 Double ellipsoid heat source model

图5 热源校核

Fig.5 Heat source check

表4 双椭球热源模型参数

Table 4 Parameters of heat source model of double ellipsoid

前半轴长/mm	后半轴长/mm	宽度/mm	深度/mm	效率
2.8	5.8	4.6	12	0.78

图6 实验变形结果

Fig.6 Cloud map of experimental deformation results

图7 A点实验等效应力

Fig.7 Experimental equivalent stress curve of Point A

图8 4种算法增材构件总变形量

Fig.8 Cloud map of the total deformations of additive components of the four algorithms

图9 特征点变形量对比

Fig.9 Comparison of deformations of feature points

表5 特征点变形量对比

Table 5 Comparison of deformations of feature points

特征点与均值	瞬态热源精度/%	热循环曲线精度/%	全热循环精度/%	固有应变精度/%
H	99.97	97.35	91.59	84.89
C	93.42	97.40	95.87	75.96
D	98.75	97.18	87.93	69.12
E	97.91	96.60	87.49	56.75
F	93.87	96.64	67.13	72.04
G	98.80	87.10	73.90	26.32
均值	96.59	95.66	85.68	65.86

图10 特征点B变形量变化

Fig.10 Deformation variation curves of Point B

图11 4种算法增材构件等效应力

Fig.11 Cloud map of the equivalent stresses of additive components of the four algorithm

图12 A点等效应力对比

Fig.12 Comparison of equivalent stress curves at Point A

图13 等效应力峰值对比

Fig.13 Comparison of equivalent stress peak values

图14 特征点B等效应力变化

Fig.14 Equivalent stress variation curves of Point B

参考文献 22

[1]	DONG Z, TORBATI-SARRAF H, HUANG C, et al. Microstructure and corrosion behaviour of structural steel fabricated by wire arc additive manufacturing (WAAM)[J]. Materials & Design, 2024,244:113158.
[2]	杜泽林. 5B06铝合金电弧增材制造构件的应力与变形控制研究[D]. 沈阳: 沈阳大学, 2020.
	DU Z L. Study on stress and deformation control of 5B06 aluminum alloy[D]. Shenyang: Shenyang University, 2020. (in Chinese)
[3]	MOHD MANSOR M S, RAJA S, YUSOF F, et al. Integrated approach to wire arc additive manufacturing (WAAM) optimization:Harnessing the synergy of process parameters and deposition strategies[J]. Journal of Materials Research and Technology, 2024,30:2478-2499.
[4]	李颖. 电弧增材制造热效应、残余应力与变形规律的研究[D]. 福州: 福州大学, 2021.
	LI Y. Research on thermal effect,residual stress and deformation law of wire and arc additive manufacturing[D]. Fuzhou: Fuzhou University, 2021. (in Chinese)
[5]	潘宇, 吕彦明, 赵鹏, 等. 电弧增材单道多层应力场数值模拟与变形分析[J]. 机械科学与技术, 2023, 42(5):765-71.
	PAN Y, LYU Y M, ZHAO P, et al. Numerical simulation and deformation analysis of single-pass multi-layer stress field in arc additive manufacturing[J]. Mechanical Science and Technology for Aerospace Engineering, 2023, 42(5):765-71. (in Chinese)
[6]	王虎. 电弧增材制造过程中温度场、应力场及变形的数值模拟[D]. 重庆: 重庆大学, 2022.
	WANG H. Numerical simulation of temperature field,stress field and deformation during wire-arc additive manufacturing[D]. Chongqing: Chongqing University, 2022. (in Chinese)
[7]	MATHEWS R, KARANDIKAR J, TYLER C, et al. Residual stress accumulation in large-scale Ti-6Al-4V wire-arc additive manufacturing[J]. Procedia CIRP, 2024,121:180-185.
[8]	XIE D Q, LÜ F, YANG Y W, et al. A review on distortion and residual stress in additive manufacturing[J]. Chinese Journal of Mechanical Engineering:Additive Manufacturing Frontiers, 2022, 1(3):100039.
[9]	GORNYAKOV V, DING J L, SUN Y L, et al. Understanding and designing post-build rolling for mitigation of residual stress and distortion in wire arc additively manufactured components[J]. Materials & Design, 2022,213:110335.
[10]	LIANG X, CHENG L, CHEN Q, et al. A modified method for estimating inherent strains from detailed process simulation for fast residual distortion prediction of single-walled structures fabricated by directed energy deposition[J]. Additive Manufacturing, 2018,23:471-486.
[11]	SUN J M, DILGER K. Thermal cycle method’s applicable conditions for predicting residual stresses in low-strength steel weldments induced by arc welding[J]. Thermal Science and Engineering Progress, 2024,47:102260.
[12]	ALHAKEEM M M, MOLLAMAHMUTOGLU M, YILMAZ O, et al. A deposition strategy for wire arc additive manufacturing based on temperature variance analysis to minimize overflow and distortion[J]. Journal of Manufacturing Processes, 2023,85:1208-1220.
[13]	MUKHERJEE T, ZHANG W, DEBROY T. An improved prediction of residual stresses and distortion in additive manufacturing[J]. Computational Materials Science, 2017,126:360-372.
[14]	潘建刚. 基于激光扫描数据的三维重建关键技术研究[D]. 北京: 首都师范大学, 2005.
	PAN J G. The reseach of the key problems of 3D reconstruction from laser scan data[D]. Beijing: Capital Normal University, 2005. (in Chinese)
[15]	ZHANG C G, SHU J P, ZHANG H, et al. Estimation of load-carrying capacity of cracked RC beams using 3D digital twin model integrated with point clouds and images[J]. Engineering Structures, 2024,310:118126.
[16]	KIM M K, WANG Q, PARK J W, et al. Automated dimensional quality assurance of full-scale precast concrete elements using laser scanning and BIM[J]. Automation in Construction, 2016,72:102-114.
[17]	孙婧妍. 高温电阻应变片应力监测可靠性测试实验研究[D]. 武汉: 武汉工程大学, 2022.
	SUN J Y. Experimental study on reliability test of high temperature resistance strain gauge stress monitoring[D]. Wuhan: Wuhan University of Engineering, 2022. (in Chinese)
[18]	陈竞瑶. AISI304不锈钢激光焊与TIG焊对比研究[D]. 上海: 上海交通大学, 2018.
	CHEN J Y. A comparative study between laser beam welding and tungsten inert gas welding of AISI304 stainless steel[D]. Shanghai: Shanghai Jiao Tong University, 2018. (in Chinese)
[19]	刘国昌. 激光电弧复合增材制造路径规划计算机仿真及工艺研究[D]. 长春: 长春理工大学, 2020.
	LIU G C. Research on computer simulation of path planning and process for laser arc hybrid additive manufacturing[D]. Changchun: Changchun University of Science and Technology, 2020. (in Chinese)
[20]	KIK T, GARAŠIĆ I, PERIĆ M, et al. Modifications of the heat source model in numerical analyses of the metal-cored arc welding process[J]. Energy, 2024,302:131811.
[21]	ABERBACHE H, MATHIEU A, BOLOT R, et al. Experimental analysis and numerical simulation of laser welding of thin austenitic stainless-steel sheets using two models:bilinear isotropic strain hardening model and Johnson-Cook model[J]. Journal of Advanced Joining Processes, 2024,9:100198.
[22]	王磊, 杜劭峰, 李红星, 等. 钛合金蒙皮-骨架结构激光焊接变形规律模拟[J]. 兵工学报, 2025, 46(3):240017. https://doi.org/10.12382/bgxb.2024.0017.
	WANG L, DU S F, LI H X, et al. Investigation of deformation laws during laser beam welding of a skin skeleton structure using numerical simulation[J]. Acta Armamentarii, 2025, 46(3):240017. (in Chinese) doi: 10.12382/bgxb.2024.0017